Chevrolet - Silverado 1500 4wd - Workshop Manual - 2010 - 2010

Factory Workshop Manual Make Chevrolet Model Silverado 1500 4wd Engine and year V8-6.0L (2010) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams Alarm Module: Diagrams Component Connector End Views Theft Deterrent Module (TDM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 7 Alarm Module: Service and Repair Theft Deterrent Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired Communications Control Module: Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired > Page 12 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired > Page 13 Communications Control Module: Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired > Page 14 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 15 Communications Control Module: Locations Harness Routing Views I/P Extension Harness Routing (SLT except Y91/MEX) 1 - JX223 (U2K/UK6/UE1) 2 - X203 (UE1/U3U/UVB) 3 - X204 (U42) 4 - X212 5 - X206 (U42) 6 X213 (COAX) 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - X301 (UQA/D07) 9 Floor Panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 16 Communications Control Module: Diagrams Component Connector End Views Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 17 Vehicle Communication Interface Module (VCIM) X3 (UE1 with UUL or UUK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 18 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement (with RPO SLT) Communications Control Module: Service and Repair Communication Interface Module Replacement (with RPO SLT) Communication Interface Module Replacement (with RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement (with RPO SLT) > Page 21 Communications Control Module: Service and Repair Communication Interface Module Replacement (without RPO SLT) Communication Interface Module Replacement (without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 30 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 36 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams Parking Assist Control Module: Diagrams Component Connector End Views Rear Object Sensor Control Module X1 (UD7) Rear Object Sensor Control Module X2 (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 43 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 44 Parking Assist Control Module: Service and Repair Rear Object Alarm Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 53 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 54 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 55 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 61 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 62 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 63 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Relay Module: > 11-01-38-001 > Feb > 11 > A/C - Excessive Cabin Moisture/Reduced Window Clearing Control Module HVAC: All Technical Service Bulletins A/C - Excessive Cabin Moisture/Reduced Window Clearing TECHNICAL Bulletin No.: 11-01-38-001 Date: February 28, 2011 Subject: Excessive Cabin Moisture / Reduced Window Clearing (Reprogram HVAC System Control Module) Models: 2010-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL All with RPO CJ3 or C67 (Manual Air Conditioning) Condition In rare cases, some customers may comment on excessive cabin moisture or difficulty keeping the windows clear in low ambient temperatures. Cause This concern may be caused by the recirculation door being in the recirculation position while the mode is set to a floor through defrost position. Correction Important DO NOT replace the HVAC control module for this concern. Revised software has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest software currently available in TIS2WEB. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Relay Module: > 10-01-38-001 > Mar > 10 > A/C - Reduced Windshield Clearing/Defrost Control Module HVAC: All Technical Service Bulletins A/C - Reduced Windshield Clearing/Defrost TECHNICAL Bulletin No.: 10-01-38-001 Date: March 02, 2010 Subject: Reduced Windshield Clearing\Defrost at Low Ambient Temperatures (Reprogram HVAC Control Module) Models: 2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with HVAC System RPOs C42, C67 or CJ3 All Built Prior to February 17, 2010 Condition In rare cases, some customers may comment that the HVAC system has reduced defrost or added difficulty keeping the windshield clear in low ambient temperatures. Cause This condition may be caused by the airflow calibrations which can contribute to the above condition. Calibration changes at the start of the 2010 model year may not meet some customers' expectations. Testing has confirmed that defrost levels will meet requirements. Correction Important DO NOT replace the HVAC Control Module for this concern. Reprogram the HVAC Control Module with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest calibrations available on TIS2WEB. Refer to HVAC System Control Module Programming and Setup in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations Memory Positioning Module: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 89 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 90 Memory Positioning Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 91 Memory Seat Module (MSM) X3 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 92 Memory Seat Module (MSM) X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 93 Memory Seat Module (MSM) X5 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 94 Memory Seat Module (MSM) X6 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 95 Memory Seat Module (MSM) X7 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 96 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 97 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P Power Door Lock Relay: Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 102 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 103 Power Door Lock Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 104 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 105 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 106 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 107 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 108 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 109 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 110 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 119 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 120 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 121 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 122 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 128 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 129 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 130 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 131 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 132 Seat Heater Control Module: Diagrams Component Connector End Views Seat Back Ventilation Heating and Cooling Module - Driver (KB6) Seat Back Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 133 Seat Climate Control Module X1 (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 134 Seat Climate Control Module X2 (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 135 Seat Climate Control Module X3 (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 136 Seat Cushion Ventilation Heating and Cooling Module - Driver (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 137 Seat Cushion Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 138 Heated Seat Control Module X1 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 139 Heated Seat Control Module X2 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 140 Heated Seat Control Module X3 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 141 Heated Seat Control Module X4 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 142 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Front Seat Heater Control Module Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Front Seat Heater Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Front Seat Heater Control Module > Page 145 Seat Heater Control Module: Service and Repair Module Replacement - Seat Climate Control Front Seat (Denali with KB6) Module Replacement - Seat Climate Control - Front Seat (Denali with KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof / Moonroof Module: Diagrams Component Connector End Views Sunroof Control Module (CF5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams Trailer Towing Relay: Diagrams Component Connector End Views Trailer Brake Control Relay (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Page 152 Trailer Towing Relay: Service and Repair Trailer Brake Control Relay Replacement (1500) Removal Procedure 1. Turn the ignition switch to the OFF position. Note: Do not remove the spare tire and wheel hoist. 2. Remove the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair). 3. Disconnect the trailer brake control relay electrical connector. Note: It is not necessary to completely remove the bolts. 4. Loosen, but do not remove, the trailer brake control relay bolts (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Page 153 5. Slide the trailer brake control relay (1) toward the center of the vehicle and remove the trailer brake control relay. Installation Procedure 1. If installing a new trailer brake control relay, hand start the 2 trailer brake control relay bolts. 2. Position the trailer brake control relay to the frame bracket. 3. Slide the trailer brake control relay (1) toward the left frame rail. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Page 154 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the trailer brake control relay bolts (1) to 6 Nm (53 lb in). 5. Connect the trailer brake control relay electrical connector. 6. Install the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams Electronic Brake Control Module: Diagrams Component Connector End Views Electronic Brake Control Module (EBCM) (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 159 Electronic Brake Control Module (EBCM) (JF3 or JF7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 160 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 161 Electronic Brake Control Module (EBCM) (JH6 or JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 162 Electronic Brake Control Module (EBCM) (JL4 except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 163 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 164 Electronic Brake Control Module (EBCM) (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 165 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 166 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Electronic Brake Control Module: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Electronic Brake Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 169 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 170 Electronic Brake Control Module: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Electronic Brake Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 175 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 176 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 177 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 178 Trailer Brake Control Module: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 179 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 180 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 181 Trailer Brake Control Module: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 except 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 182 Trailer Brake Control Module (JL1 with 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 183 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 184 Fuel Pump/Trailer Brake Control Module (Gas with JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 185 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 186 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement > Page 189 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement (1500) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: The trailer brake control module is integral to the fuel pump flow control module. 2. Remove the fuel pump flow control module (1). Refer to Fuel Pump Flow Control Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement > Page 190 1. Install the fuel pump flow control module (1). Refer to Fuel Pump Flow Control Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. If installing a new trailer brake control module, program the module. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 195 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 196 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 197 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 198 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 199 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 200 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 201 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 206 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 207 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 208 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 209 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 210 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 211 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 212 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 216 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 217 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 218 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 219 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 220 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 221 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 222 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 11-01-38-001 > Feb > 11 > A/C Excessive Cabin Moisture/Reduced Window Clearing Control Module HVAC: Customer Interest A/C - Excessive Cabin Moisture/Reduced Window Clearing TECHNICAL Bulletin No.: 11-01-38-001 Date: February 28, 2011 Subject: Excessive Cabin Moisture / Reduced Window Clearing (Reprogram HVAC System Control Module) Models: 2010-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL All with RPO CJ3 or C67 (Manual Air Conditioning) Condition In rare cases, some customers may comment on excessive cabin moisture or difficulty keeping the windows clear in low ambient temperatures. Cause This concern may be caused by the recirculation door being in the recirculation position while the mode is set to a floor through defrost position. Correction Important DO NOT replace the HVAC control module for this concern. Revised software has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest software currently available in TIS2WEB. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 10-01-38-001 > Mar > 10 > A/C Reduced Windshield Clearing/Defrost Control Module HVAC: Customer Interest A/C - Reduced Windshield Clearing/Defrost TECHNICAL Bulletin No.: 10-01-38-001 Date: March 02, 2010 Subject: Reduced Windshield Clearing\Defrost at Low Ambient Temperatures (Reprogram HVAC Control Module) Models: 2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with HVAC System RPOs C42, C67 or CJ3 All Built Prior to February 17, 2010 Condition In rare cases, some customers may comment that the HVAC system has reduced defrost or added difficulty keeping the windshield clear in low ambient temperatures. Cause This condition may be caused by the airflow calibrations which can contribute to the above condition. Calibration changes at the start of the 2010 model year may not meet some customers' expectations. Testing has confirmed that defrost levels will meet requirements. Correction Important DO NOT replace the HVAC Control Module for this concern. Reprogram the HVAC Control Module with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest calibrations available on TIS2WEB. Refer to HVAC System Control Module Programming and Setup in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11-01-38-001 > Feb > 11 > A/C - Excessive Cabin Moisture/Reduced Window Clearing Control Module HVAC: All Technical Service Bulletins A/C - Excessive Cabin Moisture/Reduced Window Clearing TECHNICAL Bulletin No.: 11-01-38-001 Date: February 28, 2011 Subject: Excessive Cabin Moisture / Reduced Window Clearing (Reprogram HVAC System Control Module) Models: 2010-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL All with RPO CJ3 or C67 (Manual Air Conditioning) Condition In rare cases, some customers may comment on excessive cabin moisture or difficulty keeping the windows clear in low ambient temperatures. Cause This concern may be caused by the recirculation door being in the recirculation position while the mode is set to a floor through defrost position. Correction Important DO NOT replace the HVAC control module for this concern. Revised software has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest software currently available in TIS2WEB. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 10-01-38-001 > Mar > 10 > A/C - Reduced Windshield Clearing/Defrost Control Module HVAC: All Technical Service Bulletins A/C - Reduced Windshield Clearing/Defrost TECHNICAL Bulletin No.: 10-01-38-001 Date: March 02, 2010 Subject: Reduced Windshield Clearing\Defrost at Low Ambient Temperatures (Reprogram HVAC Control Module) Models: 2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with HVAC System RPOs C42, C67 or CJ3 All Built Prior to February 17, 2010 Condition In rare cases, some customers may comment that the HVAC system has reduced defrost or added difficulty keeping the windshield clear in low ambient temperatures. Cause This condition may be caused by the airflow calibrations which can contribute to the above condition. Calibration changes at the start of the 2010 model year may not meet some customers' expectations. Testing has confirmed that defrost levels will meet requirements. Correction Important DO NOT replace the HVAC Control Module for this concern. Reprogram the HVAC Control Module with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest calibrations available on TIS2WEB. Refer to HVAC System Control Module Programming and Setup in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 244 Control Module HVAC: Diagrams Component Connector End Views HVAC Control Module X1 (CJ2) HVAC Control Module X2 (C67, C42 or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 245 HVAC Control Module X2 (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 246 HVAC Control Module X3 (C67, C42, CJ2 or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 247 Blower Motor Control Module X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 248 Blower Motor Control Module X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 249 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic Control Module HVAC: Service and Repair HVAC - Automatic HVAC Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 252 Control Module HVAC: Service and Repair HVAC - Manual HVAC Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 253 Control Module HVAC: Service and Repair Blower Motor Control Module Replacement Blower Motor Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations Backup Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 258 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 259 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 260 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 261 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 262 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 263 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 264 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations Center Mounted Brake Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 268 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 269 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 270 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 271 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 272 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 273 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 274 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 278 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 279 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 280 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 281 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 282 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 283 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 284 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Diagrams Hazard Flasher Relay: Diagrams Component Connector End Views Roof Beacon Relay (TRW) Emergency Vehicle Roof Lamp Relay (5Y0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Diagrams > Page 288 Wrecker Relay X1 (5X7) Wrecker Relay X2 (5X7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Diagrams > Page 289 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 293 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 294 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 295 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 296 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 297 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 298 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 299 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 303 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 304 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 305 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 306 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 307 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 308 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 309 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 313 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 314 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 315 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 316 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 317 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 318 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 319 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 323 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 324 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 325 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 326 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 327 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 328 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 329 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 330 Trailer Lighting Relay: Diagrams Component Connector End Views Trailer Stop/Turn Relay (TZ0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 336 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 337 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 342 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 343 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 344 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 345 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 346 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 347 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 348 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 349 Fuse Block - Underhood Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 350 Fuse Block - Underhood X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 351 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 352 Fuse Block - Underhood X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 353 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 354 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 355 Fuse Block - Underhood X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 356 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 357 Fuse Block - Underhood X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 358 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 359 Fuse Block - Underhood X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 360 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 361 Fuse Block - Underhood X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 362 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 363 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 364 Relay Box: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 365 Fuse Block - I/P Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 366 Fuse Block - I/P Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 367 Fuse Block - I/P X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 368 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 369 Fuse Block - I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 370 Fuse Block - I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 371 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 372 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 373 Relay Box: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 374 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 375 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 395 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 401 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 402 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 403 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 413 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 414 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 415 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 420 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 421 Body Control Module (BCM) X2 Body Control Module (BCM) X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 422 Body Control Module (BCM) X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 423 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 424 Body Control Module (BCM) X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 425 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 426 Body Control Module (BCM) X6 Body Control Module (BCM) X7 (except MEX or A52) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 427 Auxiliary Body Control Module (XBCM) X1 (EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 428 Auxiliary Body Control Module (XBCM) X2 (EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 429 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 432 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 433 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 434 Body Control Module: Service and Repair Serial Data Gateway Module Replacement Serial Data Gateway Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 448 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 453 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 454 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 455 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 464 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 465 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 466 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 472 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 477 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 478 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 479 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 484 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 485 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 486 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 487 Engine Control Module: Locations Harness Routing Views Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 488 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Engine Harness Routing - Top (4.3L) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 489 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 490 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 491 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 492 Engine Control Module (ECM) X1 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 493 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 494 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 495 Engine Control Module (ECM) X1 (LY2, LMG, LC9, LY5, LH6, L76 or L9H) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 496 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 497 Engine Control Module (ECM) X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 498 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 499 Engine Control Module (ECM) X1 (LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 500 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 501 Engine Control Module (ECM) X2 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 502 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 503 Engine Control Module (ECM) X2 (LY2, LY6 or L9H with Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 504 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 505 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 506 Engine Control Module (ECM) X2 (LMG, LC9, LY5, LH6, L76 or L9H without Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 507 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 508 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 509 Engine Control Module (ECM) X2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 510 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 511 Engine Control Module (ECM) X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 512 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 513 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 514 Engine Control Module (ECM) X3 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 515 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 516 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 517 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 518 Engine Control Module: Service and Repair Engine Control Module Replacement Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: Record the current Engine Oil Life percentage, and use a scan tool to update the NEW ECM, if replacing. Removal Procedure 1. Record the current Engine Oil Life percentage, and use a scan tool to update the NEW ECM, if replacing. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Disengage the engine wiring harness upper electrical connector retainer (2) and remove the connector (1) from the ECM. 4. Disengage the engine wiring harness lower electrical connector retainer (3) and remove the connector (4) from the ECM. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 519 5. Disengage the retainer tabs securing the ECM to the bracket. 6. Remove the ECM. Installation Procedure 1. Install the bottom ECM tabs into the bracket. 2. Push the ECM in securing the ECM to the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 520 3. Position the engine wiring harness lower electrical connector and engage the retainer (3) securing the lower connector (4) to the ECM. 4. Position the engine wiring harness upper electrical connector and engage the retainer (2) securing the upper connector (1) to the ECM. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 6. If a NEW ECM was installed, program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 524 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 525 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 526 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 527 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 528 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 529 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 530 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module (Gas except JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams > Page 535 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood Fuel Pump Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 540 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 541 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 542 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 543 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 544 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 545 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 546 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 547 Fuel Pump Relay: Locations Harness Routing Views Harness Routing Views Chassis Harness - Front Engine Compartment (31 Series) 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 548 Fuel Pump Relay: Diagrams Component Connector End Views Fuel Pump Relay - Secondary (LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 552 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 553 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 554 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 555 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 556 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 557 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 558 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams Ignition Control Module: Diagrams Component Connector End Views Ignition Control Module (ICM) (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 572 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 573 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 579 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 580 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 581 Air Bag Control Module: Locations Harness Routing Views Body Harness Routing (Regular Cab) 1 - X200 2 - G302 3 - X319 (AZ3/D07 with UQ3) 4 - JX339 (except MEX) 5 - X305 (except MEX) 6 - G304 (except MEX) 7 - J304 (AG2) 8 - J303 9 - X303 (except MEX) 10 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 11 - X275 12 - X202 13 - X500 (YE9 without AN3/DL3) 14 - X501 (YE9 without AN3/DL3) 15 - X601 (ASF) 16 - X600 (YE9 without AN3/DL3) Body Harness Routing (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 582 1 - X700 2 - G303 3 - X303 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 5 - X501 (YE9 without AN3/DL3) 6 - X275 7 - X208 (A48) 8 - X202 9 - X500 (YE9 without AN3/DL3) 10 - G301 11 - J304 12 - X200 13 - X601 (ASF) 14 - X600 (YE9 without AN3/DL3) 15 - G302 16 - JX339 17 - X305 18 - X319 (AZ3/D07 with UQ3) 19 - X800 20 - J302 21 G304 22 - X320 (A48) 23 - J303 24 - X322 (UD7) 25 - Floor Panel Body Harness Routing (Crew Cab except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 583 1 - X601 (ASF) 2 - X309 (Y91) 3 - G302 4 - J302 5 - JX339 6 - G301 7 - J304 8 - X305 9 - X800 10 - G304 11 - G307 12 - X320 (A48) 13 - J303 14 - G303 15 - X700 16 - X303 17 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 18 - X501 (YE9 without AN3/DL3) 19 X502 (ASF without YE9 or with AN3) 20 - X202 21 - X500 (YE9 without AN3/DL3) 22 - X208 (A48) 23 - X600 (YE9 without AN3/DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 584 Air Bag Control Module: Diagrams Component Connector End Views Inflatable Restraint Sensing and Diagnostic Module (SDM) X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 585 Inflatable Restraint Sensing and Diagnostic Module (SDM) X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 586 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 587 Inflatable Restraint Side Impact Module - Left (10 Series except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 588 Inflatable Restraint Side Impact Module - Left (HP2) Inflatable Restraint Side Impact Module - Right (10 Series except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 589 Inflatable Restraint Side Impact Module - Right (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 590 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Diagrams Seat Occupant Classification Module - Air Bag: Diagrams Component Connector End Views Inflatable Restraint Passenger Presence System (PPS) Module (AL0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations Auxiliary Battery Relay: Locations Harness Routing Views Auxiliary Battery Harness Routing (TP2) 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 598 Auxiliary Battery Relay: Diagrams Component Connector End Views Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X2 (TP2) Auxiliary Battery Relay X3 (TP2) Auxiliary Battery Run Relay (TP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 599 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 600 Auxiliary Battery Relay: Service and Repair Auxiliary Battery Relay Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. 3. Remove the auxiliary battery positive cable nut (6) from the battery relay stud. 4. Remove the auxiliary battery positive cable from the auxiliary battery relay. 5. Disconnect the auxiliary battery positive cable electrical connector (1) from the battery relay. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 601 6. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. 7. Remove the auxiliary battery positive cable nut (4) from the battery relay stud. 8. Remove the auxiliary battery positive cable from the auxiliary battery relay. 9. Remove the auxiliary battery relay nuts and relay. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the auxiliary battery relay and nuts and tighten to 9 Nm (80 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 602 2. Install the auxiliary battery positive cable to the auxiliary battery relay. 3. Install the auxiliary battery positive cable nut (4) to the battery relay stud and tighten to 9 Nm (80 lb in). 4. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 5. Connect the auxiliary battery positive cable electrical connector (1) to the battery relay. 6. Install the auxiliary battery positive cable to the auxiliary battery relay. 7. Install the auxiliary battery positive cable nut (6) to the battery relay stud and tighten to 9 Nm (80 lb in). 8. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 9. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 606 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 607 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 608 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 609 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 610 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 611 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 612 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Wheel Heater Control Module > Component Information > Service and Repair Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Module: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Module: > 10-03-16-001 > Jul > 10 > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tire Pressure Module: > 10-03-16-001 > Jul > 10 > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Customer Interest for Tire Pressure Monitor Receiver / Transponder: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Monitor Receiver / Transponder: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 664 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 665 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 666 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 672 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 673 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 674 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 680 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 681 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 687 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 688 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 689 Control Module: Locations Harness Routing Views Engine Chassis Harness Routing - Top Front (Diesel) 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 690 Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 691 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 692 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 693 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 694 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Power Take-Off > Power Take-Off Relay > Component Information > Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF or NQH) Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 703 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 704 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 707 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 712 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 713 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 714 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 715 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 716 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 717 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 718 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams Power Window Relay: Diagrams Component Connector End Views Sliding Rear Window Close Relay (A48) Sliding Rear Window Open Relay (A48) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Page 722 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Windshield Washer Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 727 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 728 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 729 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 730 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 731 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 732 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 733 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 737 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 738 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 739 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 740 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 741 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 742 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 743 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams Parking Assist Distance Sensor: Diagrams Component Connector End Views Object Alarm Sensor - Left Rear Corner (UD7) Object Alarm Sensor - Left Rear Middle (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 752 Object Alarm Sensor - Right Rear Corner (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 753 Object Alarm Sensor - Right Rear Middle (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 754 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement Rear Object Sensor Replacement Removal Procedure 1. Disconnect electrical from the rear object sensor. 2. Lift the locking tabs on the housing and remove the rear object sensor. Installation Procedure Note: Do not refinish previously painted sensors. Excess paint build up will cause the sensor to be inoperative. 1. Paint the rear object sensor. Refer to Basecoat/Clearcoat Paint Systems (See: Body and Frame/Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems). 2. Ensure the paint does not exceed 6 mils. Use a paint thickness gauge suitable for non-ferrous metals. Refer to Paint Gauges (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 757 Note: Ensure the silicone decoupling ring is installed on the sensor to avoid sensor failure. 3. Insert the sensor into the housing. 4. Connect the electrical connector to the rear object sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 758 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (Sierra/Silverado) Rear Object Sensor Housing Replacement (Sierra/Silverado) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 759 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (All Other Vehicles) Rear Object Sensor Housing Replacement (All Other Vehicles) 1. Remove the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () or Rear Bumper Impact Bar End Cap Replacement (). 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. Important: Do Not grind off alignment tabs. 4. Sand/grind sonic weld plastic residue from the fascia. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 760 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 761 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () or Rear Bumper Impact Bar End Cap Replacement (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair Pedal Positioning Sensor: Service and Repair Brake and Accelerator Pedal Adjuster Position Sensor Replacement (With Memory Seats) Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Disconnect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Remove the adjustable pedal position sensor bolts (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair > Page 765 5. Remove the brake and accelerator pedal adjuster position sensor (1). Installation Procedure 1. Install the brake and accelerator pedal adjuster position sensor (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair > Page 766 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the adjustable pedal position sensor bolts (1) and tighten to 2 Nm (18 lb in). 3. Connect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Install the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams Remote Switch: Diagrams Component Connector End Views Rear Seat Audio (RSA) Control X1 (UK6) Rear Seat Audio (RSA) Control X2 (UK6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 770 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Shock Sensor, Antitheft > Component Information > Diagrams Shock Sensor: Diagrams Component Connector End Views Vehicle Shock Sensor (SPO Alarm) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Steering Mounted Controls Assembly > Component Information > Service and Repair Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Tow Sensor, Antitheft > Component Information > Diagrams Tow Sensor: Diagrams Component Connector End Views Vehicle Inclination Sensor (SPO Alarm) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair Pedal Positioning Sensor: Service and Repair Brake and Accelerator Pedal Adjuster Position Sensor Replacement (With Memory Seats) Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Disconnect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Remove the adjustable pedal position sensor bolts (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair > Page 788 5. Remove the brake and accelerator pedal adjuster position sensor (1). Installation Procedure 1. Install the brake and accelerator pedal adjuster position sensor (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair > Page 789 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the adjustable pedal position sensor bolts (1) and tighten to 2 Nm (18 lb in). 3. Connect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Install the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3 or DL3) Door Lock Switch - Passenger (AU3 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 793 Door Lock/Window Switch - Driver X1 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 794 Door Lock/Window Switch - Driver X2 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 795 Door Lock/Window Switch - Driver X3 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 796 Door Lock/Window Switch - Driver X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 797 Door Lock/Window Switch - Driver X7 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 798 Door Lock/Window Switch - Passenger X1 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 799 Door Lock/Window Switch - Passenger X2 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 800 Door Lock/Window Switch - Passenger X3 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 801 Door Lock/Window Switch - Passenger X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 802 Door Lock/Window Switch - Passenger X7 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 803 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Front (with DL8 and without SLT) Door Lock Switch Replacement - Front (with DL8 and without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) > Page 806 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) > Page 807 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: Customer Interest Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 816 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 822 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Component Connector End Views Outside Rearview Mirror Switch (DL8 or DPN) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 826 Power Mirror Switch: Service and Repair Power Mirror Switch Replacement (with DL8 and without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations Power Seat Motor Position Sensor: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 830 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 831 Power Seat Motor Position Sensor: Diagrams Component Connector End Views Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 832 Seat Recline Position Sensor - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 833 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: Customer Interest Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches > Page 842 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: All Technical Service Bulletins Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches > Page 848 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 849 Power Seat Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 850 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 851 Power Seat Switch: Diagrams Component Connector End Views Seat Adjuster Switch - Driver (AG1 without AN3) Seat Adjuster Switch - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 852 Seat Adjuster Switch - Passenger (AG2 without AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 853 Seat Adjuster Switch - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 854 Seat Lumbar Switch - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 855 Seat Lumbar Switch - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster Switch Knob Replacement Driver or Passenger Seat Adjuster Switch Knob Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement > Page 858 Power Seat Switch: Service and Repair Power Seat Switch Replacement Power Seat Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement > Page 859 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams Seat Heater Switch: Diagrams Component Connector End Views Heated Seat Switch - Driver (SPO Heated Seats) Heated Seat Switch - Passenger (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 863 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Front Seat Heater Switch Replacement Seat Heater Switch: Service and Repair Front Seat Heater Switch Replacement Front Seat Heater Switch Replacement Removal Procedure 1. Remove door upper trim panel. Refer to Upper Extension Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 2. Pull the door trim panel away from the door and support the bottom of the trim panel on the door panel hooks. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair)Front Side Door Trim Panel Replacement (Except YE9 or SLT) (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 3. Disconnect the electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Front Seat Heater Switch Replacement > Page 866 4. Remove the front side door heater switch fasteners (1). 5. Remove the front side door heater switch assembly (2). Installation Procedure 1. Install the front side door heater switch assembly (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the front side door heater switch fasteners and tighten to 2 Nm (18 lb in). 3. Connect the electrical connector. 4. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair)Front Side Door Trim Panel Replacement (Except YE9 or SLT) (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations Seat Memory Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 870 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 871 Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Sunroof / Moonroof Switch: Diagrams Component Connector End Views Sunroof Switch (CF5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 875 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (Crew Cab) Removal Procedure 1. Remove the overhead console in order to access the sunroof switch. Refer to Roof Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Roof Console Replacement). 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat-bladed tool, carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. Installation Procedure 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. 4. Install the overhead console to the roof. Refer to Roof Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Roof Console Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams Brake Booster Vacuum Sensor: Diagrams Component Connector End Views Brake Booster Vacuum Sensor (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams > Page 880 Brake Booster Vacuum Sensor: Service and Repair Power Brake Booster Vacuum Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views Brake Fluid Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 884 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement (Non-Hybrid) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Brake Master Cylinder Pressure Sensor (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Page 888 Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Master Cylinder Pressure Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Service and Repair Braking Sensor/Switch: Service and Repair Brake Master Cylinder Primary Piston Position Sensor Replacement Removal Procedure Note: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Disconnect the brake master cylinder (BMC) primary piston position sensor electrical connector. 4. Remove the 2 BMC primary piston position sensor screws (1). 5. Remove the primary piston position sensor (2). Tilt the rear of the position sensor downward and remove the sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Service and Repair > Page 892 1. Install the BMC primary piston position sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 2 BMC primary piston position sensor screws (1) and tighten to 10 Nm (89 lb in). 3. Connect the primary piston position sensor electrical connector. 4. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics). 5. If necessary, connect a battery charger to the 12V battery. Refer to Battery Charging (See: Starting and Charging/Battery/Service and Repair/Procedures) 6. Install a scan tool to the vehicle. Note: The ignition switch must remain in the ON position with the engine OFF during this procedure. 7. Turn the ignition ON with the engine OFF. 8. Using the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Module Setup 6. Select BMC Primary Piston Position Relearn and follow the instructions on the scan tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams Lateral Accelerometer: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams > Page 896 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams > Page 897 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Page 901 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Page 902 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams Wheel Speed Sensor: Diagrams Component Connector End Views Wheel Speed Sensor (WSS) - Left Front (10 Series) Wheel Speed Sensor (WSS) - Left Front (except 10 Series) Wheel Speed Sensor (WSS) - Left Rear (JL4 or HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 906 Wheel Speed Sensor (WSS) - Right Front (10 Series) Wheel Speed Sensor (WSS) - Right Front (except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 907 Wheel Speed Sensor (WSS) - Right Rear (JL4 or HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Front Wheel Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 910 Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Front Wheel Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 911 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 912 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 913 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 914 Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Dust Warning) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 915 2. Disconnect the wheel speed sensor electrical connector (1). 3. Release the wheel speed sensor electrical connector and sensor harness clips (2) from the inboard frame rail. 4. Remove the wheel speed sensor bolt (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 916 5. Remove the wheel speed sensor (1) from the rear axle. Installation Procedure 1. Install the wheel speed sensor (1) to the rear axle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 917 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the wheel speed sensor bolt (1) and tighten to 9 Nm (80 lb in). 3. Connect the wheel speed sensor electrical connector (1). 4. Install the wheel speed sensor electrical connector and sensor harness clips (2) to the inboard frame rail. 5. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 918 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Ring Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Ring Replacement Special Tools * J-8092 - Driver Handle * J-21128 - Axle Pinion Oil Seal Installer * J-23690 - Bearing Installer * J-2619-01 - Slide Hammer * J-45857 - Tone Wheel and/or Bearing Remover * J-45860 - Tone Ring Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). 4. Remove the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 5. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 6. Remove the axle shaft seal, the bearing and the wheel speed sensor ring from the axle housing using the J-2619-01 - Slide Hammer (1) and the J-45857 - Tone Wheel and/or Bearing Remover (2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 919 1. Install the wheel speed sensor ring using the J-45860 - Tone Ring Installer (1) and the J-8092 Driver Handle (2). 2. Drive the wheel speed sensor ring into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft bearing using the J-23690 - Bearing Installer (1) and the J-8092 - Driver Handle (2). 4. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 920 5. Install the axle shaft seal using the J-21128 - Axle Pinion Oil Seal Installer. 6. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 7. Install the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 8. Install the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 9. Install the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). 10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 11. Fill the rear axle. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement). 12. Lower the vehicle. Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Ring Replacement Removal Procedure Note: The wheel speed sensor ring is integral to the wheel hub and must be replaced as an assembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 4. Remove the rear axle hub. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). Installation Procedure 1. Install the rear axle hub. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). 2. Install the rear brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 921 See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 3. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams Yaw Rate Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams > Page 925 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams > Page 926 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Yaw Rate Sensor: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 929 Yaw Rate Sensor: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 940 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 941 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 942 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 943 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 949 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 950 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 951 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 952 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 958 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 963 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 964 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 965 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 974 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 975 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 976 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 982 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 987 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 988 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 989 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 998 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 999 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 1000 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1001 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1002 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor. 3. Remove the ECT sensor. Installation Procedure Caution: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1003 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ECT sensor and tighten to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor. 4. Refill the cooling. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 1008 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 1009 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 1010 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 1011 washer (707). 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 1012 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views Ambient Air Temperature Sensor (CJ2 or C67) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 1017 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement Removal Procedure 1. Remove the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 2. Remove the left center pillar assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair/Roof Rail Rear Assist Handle Replacement). 3. Remove the center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Garnish Molding Replacement). 4. Remove the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair). 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. Installation Procedure 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Page 1021 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair). 5. Install the left center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Garnish Molding Replacement). 6. Install the left center assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair/Roof Rail Rear Assist Handle Replacement). 7. Install the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Left Side Duct Air Temperature Sensor Replacement - Lower Left Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side > Page 1026 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Right Side Duct Air Temperature Sensor Replacement - Lower Right Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side > Page 1027 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Upper Left Side Duct Air Temperature Sensor Replacement - Upper Left Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side > Page 1028 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Upper Right Side Duct Air Temperature Sensor Replacement - Upper Right Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams Evaporator Temperature Sensor / Switch: Diagrams Component Connector End Views Air Temperature Sensor - Inside (CJ2) Air Temperature Sensor - Lower Left (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 1032 Air Temperature Sensor - Lower Right (CJ2) Air Temperature Sensor - Upper Left (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 1033 Air Temperature Sensor - Upper Right (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 1034 Evaporator Temperature Sensor (except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Refrigerant Pressure Sensor (Gas except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning Cycling Switch Replacement (Non-HP2) Air Conditioning Cycling Switch Replacement (Non-HP2) Removal Procedure 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. Installation Procedure 1. Install the new O-ring seal to the switch. Refer to Air Conditioning O-Ring Seal Replacement (See: Heating and Air Conditioning/Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning O-Ring Seal Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the A/C low pressure switch to the accumulator and tighten to 6 Nm (53 lb in). 3. Connect the electrical connector to the A/C low pressure switch. 4. Leak test the fittings of the components using the J 39400-A . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) > Page 1040 Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (Non-HP2) Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (Non-HP2) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Disconnect the electrical connector from the A/C refrigerant pressure sensor. 2. Remove the A/C refrigerant pressure sensor (1) from the condenser tube. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) > Page 1041 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the A/C refrigerant pressure sensor (1). Tighten the switch to 6 Nm (53 lb in). 2. Connect the electrical connector to the A/C refrigerant pressure sensor. 3. Leak test the fittings of the components using the J 39400-A . 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic Refrigerant Temperature Sensor: Service and Repair HVAC - Automatic Air Conditioning Refrigerant Temperature Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic > Page 1046 Refrigerant Temperature Sensor: Service and Repair HVAC - Manual Air Conditioning Refrigerant Temperature Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams Solar Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C67, C42 or MEX) Ambient Light/Sunload Sensor (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 1050 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 1051 Solar Sensor: Service and Repair Sun Load Temperature Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Dimmer Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Page 1059 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Page 1060 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Backup Lamp Switch: Diagrams Component Connector End Views Backup Lamp Switch (TZ0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission Backup Lamp Switch: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Backup Lamp Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 1070 Backup Lamp Switch: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the backup lamp switch electrical connector (3). 3. Remove the backup lamp switch. Installation Procedure Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). Note: The backup lamp switch has pre-applied thread sealant on the threads. 1. Install the backup lamp switch. Tighten the switch to 37 Nm (27 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 1071 2. Connect the backup lamp switch electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams Brake Light Switch: Diagrams Component Connector End Views Stop Lamp Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (With Adjustable Pedals) Stop Lamp Switch Replacement (With Adjustable Pedals) Removal Procedure 1. Apply the park brake. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Disconnect the stoplamp switch electrical connector. 4. Remove the power vacuum brake booster pushrod retainer bolt (1). 5. Remove the power vacuum brake booster pushrod retainer (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) > Page 1077 6. Slide the power vacuum brake booster pushrod off of the brake pedal pin and remove the stoplamp switch (1). Installation Procedure 1. Install the stoplamp switch (1) to the power vacuum brake booster pushrod. 2. Install the power vacuum brake booster pushrod with the stoplamp switch to the brake pedal pin. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) > Page 1078 3. Install the power vacuum brake booster pushrod retainer (1). 4. Rotate the pushrod retainer 360 degrees to verify the retainer is fully engaged in the groove on the brake pedal pin. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the power vacuum brake booster pushrod retainer bolt (1) and tighten to 10 Nm (89 lb in). 6. Connect the stoplamp switch electrical connector. 7. Install the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) > Page 1079 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Without Adjustable Pedals) Stop Lamp Switch Replacement (Without Adjustable Pedals) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams Combination Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Page 1083 Turn Signal/Multifunction Switch X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Fog Lamp Switch Replacement (with RPO SLT) Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (with RPO SLT) Fog Lamp Switch Replacement (with RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Fog Lamp Switch Replacement (with RPO SLT) > Page 1088 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (without RPO SLT) Fog Lamp Switch Replacement (without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Component Connector End Views Roof Beacon Switch (5X7, 5Y0 or TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement (with RPO SLT) Headlamp Switch: Service and Repair Headlamp Switch Replacement (with RPO SLT) Headlamp Switch Replacement (with RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement (with RPO SLT) > Page 1096 Headlamp Switch: Service and Repair Headlamp Switch Replacement (without RPO SLT) Headlamp Switch Replacement (without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair Steering Wheel Horn Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1103 Turn Signal/Multifunction Switch X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement > Page 1106 Turn Signal Switch: Service and Repair Turn Signal Switch Cancel Cam Position Plate Replacement Turn Signal Switch Cancel Cam Position Plate Replacement Tools Required * J 23653-SIR Steering Column Lock Plate Compressor * J 42137 Cam Orientation Plate Adapter Removal Procedure 1. Remove the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Important: DISCARD the old steering shaft lock plate ring. 2. Remove the following parts from the steering shaft: 1. Steering shaft lock plate retaining ring (1) using compressor J 23653-SIR and adapter J 42137 . 2. Turn signal switch cancel cam position plate (2) 3. Turn signal switch cancel cam (3) Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement > Page 1107 Important: Use a NEW steering shaft lock plate retaining ring. 1. Install the following parts onto the steering shaft: 1. Lubricate the turn signal switch cancel cam (3) with GM P/N 12377900 (Canadian P/N 10953529). 2. Turn signal switch cancel cam position plate (2) 3. Steering shaft lock plate retaining ring (1) using compressor J 23653-SIR and adapter J 42137 . 2. Install the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1113 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1114 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 2. Remove the accelerator pedal bolts. 3. Remove the accelerator pedal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1115 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1119 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1120 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1121 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1122 Installation Procedure Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the MAF/IAT sensor adapter clamp. Tighten the clamp to 4 Nm (35 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 1126 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 1127 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1131 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1132 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1133 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1134 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1135 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1136 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement (Except RPOs LY2, LY5, LH6 and LMG) Removal Procedure Note: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the CMP sensor wire harness. 3. Remove the 3 CMP sensor wire harness bolts (738). 4. Disconnect the CMP sensor wire harness electrical connectors from the CMP sensor and the CMP actuator magnet. 5. Remove the CMP sensor wire harness (737). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1137 6. Remove the CMP sensor (703) and O-ring seal (704). Installation Procedure 1. Inspect the CMP O-ring seal for cuts or damage. If the seal is not cut or damaged, it may be used again. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal (704) onto the sensor. 4. Instal the CMP sensor (703) to the front cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1138 5. Install the CMP sensor wire harness (737). 6. Connect the CMP sensor wire harness electrical connectors to the CMP sensor and the CMP actuator magnet. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the 3 CMP sensor wire harness bolts (738). Tighten the bolts to 12 Nm (106 lb in). 8. Connect the engine wiring harness electrical connector (1) to the CMP sensor wire harness. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Clutch Switch: Diagrams Component Connector End Views Clutch Pedal Position (CPP) Switch (TZ0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1150 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1151 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1152 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1153 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1159 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1160 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1161 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1162 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1163 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1164 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor. 3. Remove the ECT sensor. Installation Procedure Caution: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1165 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ECT sensor and tighten to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor. 4. Refill the cooling. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 1169 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 1170 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 1171 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The Crankshaft Position System Variation Learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * An engine replacement * A engine control module (ECM) replacement * A crankshaft balancer replacement * A crankshaft replacement * A crankshaft position sensor replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The ECM monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position System Variation Learn Procedure. 1. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 2. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 3. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 4. Enable the CKP System Variation Learn Procedure with a scan tool. 5. Quickly apply and release the accelerator pedal. 6. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 7. The scan tool displays Learn Status: Learned this ignition. 8. Once the Learn Procedure has successfully completed, and in order to store the crankshaft position system variation values in the ECM, turn OFF the ignition and verify all vehicle systems are OFF. This may take up to 2 minutes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 1172 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure Note: Perform the Crankshaft Position System Variation Learn (See: Testing and Inspection) whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 1173 5. Remove the CKP sensor. Installation Procedure 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 1178 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 1179 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 1180 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Reg Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Reg Cab With 26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 1181 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 1182 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 1183 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 gal Tank) Fuel Level Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 gal Tnk) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 1184 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 1185 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 Gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 1191 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 1192 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 REG Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Reg Cab With 26 Gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 1193 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 1194 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15/25 REG/Ext/Crw Cab With 34 gal Tank) Fuel Tank Pressure Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 1195 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Page 1199 Installation Procedure Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the MAF/IAT sensor adapter clamp. Tighten the clamp to 4 Nm (35 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1203 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 1206 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (4) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 1207 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 1208 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (2) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (LU3) Manifold Absolute Pressure (MAP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 1212 Manifold Absolute Pressure (MAP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 1213 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 1214 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (4) from the manifold absolute pressure (MAP) sensor. 3. Remove the MAP sensor retainer. 4. Remove the MAP sensor. Installation Procedure Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 1215 1. Install the MAP sensor. 2. Install the MAP sensor retainer. 3. Connect the engine harness wiring electrical connector (4) to the MAP sensor. 4. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 1219 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 1220 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 1221 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 1222 washer (707). 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 1223 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Harness Routing Views Heated Oxygen Sensor (HO2S) Jumper Harness Routing (LY6) 1 - X125 2 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1227 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LU3) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (Gas except LU3 and except ZW9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1228 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY6 or L96 with ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1229 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (Gas except LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1230 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (Gas except LU3 and except ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY6 or L96 with ZW9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1231 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1232 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 1235 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 1236 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 1237 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Unbolt the front propeller shaft from the front differential, if equipped with four wheel drive (4WD). Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 3. For vehicles equipped with a 4L60-E/4L70-E automatic transmission perform the following steps, for vehicles equipped with a 6L80-E automatic transmission proceed to step 7. 4. Remove the connector position assurance (CPA) retainer. 5. Disconnect the engine wiring harness electrical connector (2) from the HO2S. 6. Remove the HO2S electrical connector clip (1) from the fuel line clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 1240 7. Remove the CPA retainer (2). 8. Remove the engine wiring harness electrical connector clip (1) from the fuel line clip. 9. Disconnect the engine wiring harness electrical connector (3) from the HO2S. Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 10. Remove the HO2S (1 or 2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 1241 Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 2. Install the HO2S (1 or 2). Tighten the sensor to 42 Nm (31 lb ft). 3. For vehicles equipped with a 4L60-E/4L70-E automatic transmission perform the following steps, for vehicles equipped with a 6L80-E automatic transmission proceed to step 7. 4. Install the HO2S electrical connector clip (1) to the fuel line clip. 5. Connect the engine wiring harness electrical connector (2) to the HO2S. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 1242 6. Install the CPA retainer. 7. Connect the engine wiring harness electrical connector (3) to the HO2S. 8. Install the engine wiring harness electrical connector clip (1) to the fuel line clip. 9. Install the CPA retainer (2). 10. Install the front propeller shaft to the front differential, if equipped with 4WD. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 11. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 1243 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the connector position assurance (CPA) retainer (1). 3. Disconnect the HO2S electrical connector from the engine wiring harness electrical connector (3). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 4. Remove the HO2S (5). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 1244 Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 2. Install the HO2S (5). Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the HO2S electrical connector to the engine wiring harness electrical connector (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 1245 4. Install the CPA retainer (1). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 1246 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) 1. Remove the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 2. Remove the connector position assurance (CPA) retainer (2). 3. Disconnect the HO2S electrical connector (7) from the engine wiring harness electrical connector (1). 4. Remove the HO2S clip (8) from the engine wiring harness. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 1247 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) 5. Remove the HO2S (3). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution) 2. Install the HO2S (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 1248 Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the HO2S electrical connector (7) to the engine wiring harness electrical connector (1). 4. Install the CPA retainer (2). 5. Install the HO2S clip (8) to the engine wiring harness. 6. Install the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 1249 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the connector position assurance (CPA) retainer (5). 3. Disconnect the engine wiring harness electrical connector (4) from the HO2S electrical connector (3). 4. Remove the HO2S electrical connector clip from the engine harness clip (6). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 1250 5. Remove the HO2S (4). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution) 2. Install the HO2S (4). Tighten the sensor to 42 Nm (31 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 1251 3. Install the HO2S electrical connector clip to the engine harness clip (6). 4. Connect the engine wiring harness electrical connector (4) to the HO2S electrical connector (3). 5. Install the CPA retainer (5). 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Parking Lock and Manual Shift Detent Lever with Shaft Position Switch Assembly 78 - Steel Cup Plug 79 - Parking Brake Pawl Shaft 80 - Parking Pawl Return Spring 81 - Parking Brake Pawl 82 - Manual Shaft Seal 84 - Manual Shaft - Model Dependent 85 - Parking Lock Actuator Assembly 86 - Parking Lock Bracket 87 - Parking Lock Bracket Bolt 88 - Manual Shift Detent Lever with Shaft Position Switch Assembly 89 - Manual Valve Link 92 - Manual Shift Detent Lever Hub Pin Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1256 Transmission Position Switch/Sensor: Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1257 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1260 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1261 Transmission Position Switch/Sensor: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 Nm (9 lb ft). 3. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Install the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1262 Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations Vehicle Speed Sensor: Component Locations Disassembled Views Case and Associated Parts (1 of 2) 1 - Torque Converter Assembly - Size Model Dependent 2 - Pump to Case Bolt 3 - Pump to Case Bolt O-Ring 4 - Oil Pump Assembly 5 - A/T Fluid Pump Seal - Pump to Case 6 - Pump Cover to Case Gasket 7 - Case Bushing 9 - Transmission Vent Assembly 11 - Case Servo Plug 12 - Servo Return Spring 13 - 2nd Apply Piston Pin 14 - Retainer Ring - 2nd Apply Piston 15 - Servo Cushion Spring Retainer 16 - Servo Cushion Spring - Outer 17 - 2nd Apply Piston 18 - Oil Seal Ring - 2nd Apply Piston - Outer 19 - Oil Seal Ring - 2nd Apply Piston - Inner Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 1267 20 - Servo Piston Housing - Inner 21 - O-Ring Seal 22 - Servo Apply Pin Spring 23 - Servo Apply Pin Washer 24 - Retainer Ring - Apply Pin 25 - 4th Apply Piston 26 - Oil Seal Ring - 4th Apply Piston - Outer 27 - O-Ring Seal - 2-4 Servo Cover 28 - 2-4 Servo Cover 29 - Servo Cover Retaining Ring 30 - Case Extension to Case Seal 31 - Case Extension - Model Dependent 32 Case Extension to Case Bolt 33 - Case Extension Bushing 34 - Case Extension Oil Seal Assembly - Model Dependent 34 - Case Extension Oil Seal Assembly - Model Dependent 35 - Speed Sensor Retaining Bolt 36 - Vehicle Speed Sensor (VSS) 37 - O-Ring Seal - VSS to Case Extension 71 Filter Seal 72 - Transmission Oil Filter Assembly - Model Dependent 73 - Transmission Oil Pan Gasket 74 - Chip Collector Magnet 75 - Transmission Oil Pan - Model Dependent 76 Transmission Oil Pan Screw 94 - Converter Housing to Case Bolt 95 - Oil Cooler Quick Connector 96 - Oil Cooler Quick Connect Clip 97 - Converter Housing Access Hole Plug - Model Dependent 98 - Converter Bolt Inspection Plate - Model Dependent 99 - Cup D4 Orifice Plug 102 - Converter Housing - Model Dependent 103 - Main Section Case - Model Dependent 105 - Servo Cushion Spring - Inner - Model Dependent Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 1268 Vehicle Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 1269 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) (M30, TZ0, MYC and MW7or M99 with NQG or NQF) Vehicle Speed Sensor (VSS) (MW7 except NQG or NQF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 1270 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the VSS bolt (2). Tighten the bolt to 11 Nm (97 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1273 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1274 Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1275 Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1276 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the VSS and O-ring seal. Tighten the VSS to 16 Nm (12 lb ft). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1277 Vehicle Speed Sensor: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1278 Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the VSS bolt (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1279 Tighten the bolt to 11 Nm (97 lb in). 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1280 Tremec 5-Speed (TZ0) - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1281 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the VSS and O-ring seal. Tighten the VSS to 16 Nm (12 lb ft). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1282 MP 1625/1626-NQF - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1283 MP 3023/3024-NQH - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1284 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1289 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1290 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 2. Remove the accelerator pedal bolts. 3. Remove the accelerator pedal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1291 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1295 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1296 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1297 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1298 Installation Procedure Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the MAF/IAT sensor adapter clamp. Tighten the clamp to 4 Nm (35 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams Fuel Pressure Sensor/Switch: Diagrams Component Connector End Views Fuel Pressure Sensor (Gas except LU3 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 1302 Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the chassis wiring harness electrical connector (1) from the fuel pressure sensor. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. 4. Remove the fuel pressure sensor from the fuel line. 5. Remove and discard the fuel pressure sensor O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 1303 1. Lubricate a NEW fuel pressure sensor O-ring seal with clean engine oil. 2. Install the NEW fuel pressure sensor O-ring seal onto the fuel line fitting. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the fuel pressure sensor to the fuel line. Tighten the sensor to 15 Nm (11 lb ft). 5. Connect the chassis wiring harness electrical connector (1) to the fuel pressure sensor. 6. Lower the vehicle. 7. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 1304 4. Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1309 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1310 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1311 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1312 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1313 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1314 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement (Except RPOs LY2, LY5, LH6 and LMG) Removal Procedure Note: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the CMP sensor wire harness. 3. Remove the 3 CMP sensor wire harness bolts (738). 4. Disconnect the CMP sensor wire harness electrical connectors from the CMP sensor and the CMP actuator magnet. 5. Remove the CMP sensor wire harness (737). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1315 6. Remove the CMP sensor (703) and O-ring seal (704). Installation Procedure 1. Inspect the CMP O-ring seal for cuts or damage. If the seal is not cut or damaged, it may be used again. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal (704) onto the sensor. 4. Instal the CMP sensor (703) to the front cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1316 5. Install the CMP sensor wire harness (737). 6. Connect the CMP sensor wire harness electrical connectors to the CMP sensor and the CMP actuator magnet. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the 3 CMP sensor wire harness bolts (738). Tighten the bolts to 12 Nm (106 lb in). 8. Connect the engine wiring harness electrical connector (1) to the CMP sensor wire harness. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1320 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1321 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1322 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The Crankshaft Position System Variation Learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * An engine replacement * A engine control module (ECM) replacement * A crankshaft balancer replacement * A crankshaft replacement * A crankshaft position sensor replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The ECM monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position System Variation Learn Procedure. 1. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 2. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 3. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 4. Enable the CKP System Variation Learn Procedure with a scan tool. 5. Quickly apply and release the accelerator pedal. 6. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 7. The scan tool displays Learn Status: Learned this ignition. 8. Once the Learn Procedure has successfully completed, and in order to store the crankshaft position system variation values in the ECM, turn OFF the ignition and verify all vehicle systems are OFF. This may take up to 2 minutes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1323 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure Note: Perform the Crankshaft Position System Variation Learn (See: Testing and Inspection) whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1324 5. Remove the CKP sensor. Installation Procedure 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 1330 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 1331 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note: The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 1332 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1336 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 1339 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (4) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 1340 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 1341 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (2) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Diagrams Air Bag Deactivation Switch: Diagrams Component Connector End Views Inflatable Restraint I/P Module Disable Switch (C99 or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Diagrams > Page 1346 Air Bag Deactivation Switch: Service and Repair Instrument Panel Inflatable Restraint Module Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams Impact Sensor: Diagrams Component Connector End Views Inflatable Restraint Front End Sensor - Left (10 Series) Inflatable Restraint Front End Sensor - Right (10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 1350 Inflatable Restraint Front End Sensor (except 10 Series) Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 1351 Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended or Crew Cab with ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 1352 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended or Crew Cab with ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement Inflatable Restraint Front End Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1355 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1356 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1357 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab, Rear Door) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab, Rear Door) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1358 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1359 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Extended Cab, Rear Door ) Inflatable Restraint Side Impact Sensor Replacement (Extended Cab, Rear Door ) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1360 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1364 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1365 Seat Belt Buckle Switch: Diagrams Component Connector End Views Seat Belt Buckle - Driver Seat Belt Buckle - Passenger X1 (10 Series without MEX) Seat Belt Buckle - Passenger X2 (AL0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1366 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 1371 Seat Occupant Sensor: Service and Repair Inflatable Restraint Passenger Presence System Replacement - Front (without HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 1372 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations Seat Position Sensor: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 1376 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 1377 Seat Position Sensor: Diagrams Component Connector End Views Inflatable Restraint Seat Position Sensor - Driver (10 Series except MEX) Inflatable Restraint Seat Position Sensor - Passenger (10 Series except Crew Cab or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 1378 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 1379 Seat Position Sensor: Service and Repair Inflatable Restraint Seat Position Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams > Page 1384 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams > Page 1385 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 1391 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 1392 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note: The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 1393 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1401 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1402 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1403 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1404 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1405 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1406 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1413 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1414 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1415 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1416 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1417 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1418 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 1424 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 1425 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 1428 Tighten the sensor nut to 7 Nm (62 lb in). Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 1429 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 1430 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in). Note: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Note: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 1431 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 1445 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 1446 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 1447 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 1453 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 1454 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 1455 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 1456 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Parking Lock and Manual Shift Detent Lever with Shaft Position Switch Assembly 78 - Steel Cup Plug 79 - Parking Brake Pawl Shaft 80 - Parking Pawl Return Spring 81 - Parking Brake Pawl 82 - Manual Shaft Seal 84 - Manual Shaft - Model Dependent 85 - Parking Lock Actuator Assembly 86 - Parking Lock Bracket 87 - Parking Lock Bracket Bolt 88 - Manual Shift Detent Lever with Shaft Position Switch Assembly 89 - Manual Valve Link 92 - Manual Shift Detent Lever Hub Pin Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1461 Transmission Position Switch/Sensor: Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1462 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1465 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1466 Transmission Position Switch/Sensor: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 Nm (9 lb ft). 3. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Install the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1467 Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Speed Sensor: Component Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 1472 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Oil Pump Assembly 200 - Pump Body 201 - Oil Seal Ring - Slide to Wear Plate 202 - O-Ring Seal - Slide Seal Back-Up 203 - Pump Slide 204 - Pivot Pin Spring 205 - Pivot Slide Pin 208 - Pump Slide Seal Support 209 Pump Slide Seal 210 - Pump Vane Ring 210 - Pump Vane Ring 211 - Rotor Guide 212 - Oil Pump Rotor 213 - Pump Vane 214 - Stator Shaft 215 - Pump Cover 216 - Pressure Regulator Valve Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 1473 217 - Pressure Regulator Valve Spring 218 - Pressure Regulator Isolator Spring 219 - Reverse Boost Valve 220 - Reverse Boost Valve Sleeve 221 - Oil Pump Reverse Boost Valve Retaining Ring 222 - Oil Pump Converter Clutch Valve Retaining Ring 223 - Stop Valve 224 - Converter Clutch Valve - Model Dependent 227 - Pressure Relief Bolt Rivet 228 - Pressure Relief Ball 229 Pressure Relief Spring 230 - Oil Seal Ring - Stator Shaft 231 - Oil Pump Cover Screen Seal 232 Oil Pump Cover Screen 233 - Bolt M8 X 1.25 X 40 - Cover to Body 234 - Stator Shaft Bushing Front 235 - Oil Pump Cover Plug - FWD Clutch Feed 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 237 - Check Valve Retainer and Ball Assembly 237 - Check Valve Retainer and Ball Assembly 238 - Converter Clutch Signal Orifice - Cup Plug 240 - Cup Orifice Plug 241 Stator Shaft Bushing - Rear 242 - Pump Body Bushing 243 - Oil Seal Assembly 244 - Fluid Seal Retainer 245 - A/T Fluid Pump Slide Outer Spring 246 - Converter Clutch Valve Spring 247 - A/T ISS Attaching Bolt - Model Dependent 249 - O-ring 250 - A/T Input Speed Sensor (ISS) Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 1474 Transmission Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1475 Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1476 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1477 Transmission Speed Sensor: Service and Repair Input and Output Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 1481 Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection Clutch Pedal Position Sensor Learn Important: The clutch pedal position (CPP) sensor learn procedure is required when the following service procedures have been performed regardless of whether DTC P080A is set: * An engine control module (ECM) replacement * A CPP sensor replacement * Any repairs which affect the CPP sensor relationship 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P080A, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select Clutch Pedal Position Learn under Module Setup in Manual Transmission, and perform the following instructions displayed on the scan tool screen. Important: The CPP sensor learn procedure cannot be performed more than once per ignition cycle. The clutch pedal needs to be fully depressed and held steady throughout this procedure in order to perform a correct learning. 4. The scan tool will display under CPP Learn Status: Not Learned, In Process, Complete, Fail Low Volt, Fail - High Volt, or Fail Moving. The scan tool will display under CPP Learn Status Complete if the process was successful. 5. If the scan tool indicates that DTC P080A ran and passed this ignition the CPP sensor learn procedure is complete. If the scan tool indicates DTC P080A failed or did not run this ignition, refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission). If any other DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC. 6. Turn OFF the ignition for 30 seconds after the learn procedure has successfully completed in order to store the CPP sensor variation values in ECM history. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 1486 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Engine Start Switch Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Remove the plastic retainer (1) tabs from the clutch pedal position switch (2). 3. Remove the clutch pedal position switch (2) from the pushrod. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 1487 1. Install the clutch pedal position switch (2) to the pushrod. 2. Install the plastic retainer (1) tabs to the clutch pedal position switch (2). 3. Connect the clutch pedal position switch electrical connector (1). Warning Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged. 4. Perform the clutch pedal position sensor learn procedure. Refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission) or Clutch Pedal Position Sensor Learn (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Harness Routing Views Engine Harness Routing - Rear (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Dash Panel 2 - Transmission 3 - X175 (M30) 4 - Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 1496 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF or NQH) Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 1497 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 1500 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 1501 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 1502 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Page 1509 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the speed sensor with a NEW O-ring. Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1514 Power Window Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3 or DL3) Door Lock Switch - Passenger (AU3 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1515 Door Lock/Window Switch - Driver X1 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1516 Door Lock/Window Switch - Driver X2 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1517 Door Lock/Window Switch - Driver X3 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1518 Door Lock/Window Switch - Driver X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1519 Door Lock/Window Switch - Driver X7 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1520 Door Lock/Window Switch - Passenger X1 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1521 Door Lock/Window Switch - Passenger X2 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1522 Door Lock/Window Switch - Passenger X3 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1523 Door Lock/Window Switch - Passenger X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1524 Door Lock/Window Switch - Passenger X7 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1525 Sliding Rear Window Switch (A48) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1526 Window Switch - Driver X1 (A31 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1527 Window Switch - Driver X2 (A31 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1528 Window Switch - Left Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1529 Window Switch - Passenger (A31 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1530 Window Switch - Right Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1531 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Power Window Switch: Service and Repair Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 1534 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Extended Cab) Rear Side Door Window Switch Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 1535 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Crew Cab) Rear Side Door Window Switch Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 1536 Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 1537 Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Diagrams Rain Sensor: Diagrams Component Connector End Views Windshield Outside Moisture Sensor (CE1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Service and Repair > Windshield Outside Moisture Sensor Replacement Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Replacement Windshield Outside Moisture Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Service and Repair > Windshield Outside Moisture Sensor Replacement > Page 1544 Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Lens Replacement Windshield Outside Moisture Sensor Lens Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams Washer Fluid Level Switch: Diagrams Component Connector End Views Windshield Washer Fluid Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Page 1548 Washer Fluid Level Switch: Service and Repair Windshield Washer Solvent Level Switch Replacement (Chevrolet) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1554 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1555 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1556 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1557 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1558 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1559 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1560 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications > Page 1563 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications > Page 1564 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1567 Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1568 Alignment: Description and Operation Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1569 Alignment: Description and Operation Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1570 Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Toe Description Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1571 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1572 Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if equipped. Wander Description Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1573 Alignment: Testing and Inspection Trim Height Inspection Note: Before performing any of the following adjustment procedures, inspect the entire suspension system for worn or damaged suspension components. Replace those components before any measurements or adjustments are performed. Also check for any collision damage. Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause the vehicle to bottom over bumps, damage to the suspension components, and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: * Ensure the vehicle is on a level surface, such as an alignment rack. * Set the tire pressures to the pressure shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). * Ensure that the suspension is fully supporting the vehicle. * If the vehicle is equipped with automatic level control, ensure that the system is functioning properly. * Check for installed after market accessories or modifications that could affect trim height measurements: - Tire and wheel sizes other than production - Lifting or lowering kits - Wheel Opening Flares - Ground Effects * Ensure that the passenger and rear compartments are empty, except for the spare tire. * Check the fuel level. Add additional weight if necessary to simulate a full tank of fuel. (One U.S. gallon of gasoline weighs approximate 6.5 lbs. One liter of gasoline weighs 0.70 kg.) * Close all doors, lift gate/trunk and the hood. * Remove the alignment rack floating pins. Z Height Measurement Note: For vehicles equipped with torsion bars, check the Z height before performing the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use adjust arms in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Jounce the front suspension of the vehicle by pushing the vehicle down and lifting up. 2. Allow the vehicle to settle and take a measurement. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1574 Note: Perform steps 3-9 for both sides of the vehicle. 3. Point A is the contact surface of the steering knuckle for the levels. 4. Set the top edge of the level on the reference surface of the steering knuckle (C) and extend the level directly under the front end of the front attachment bolt of the lower control arm (A). 5. While keeping the level in contact with the knuckle reference surface, adjust the level up/down until the bubble indicates it is horizontally level. 6. Measure the distance between the center of the bolt and the top of the level for your first measurement 7. Keep the top edge of the level on the reference surface of the steering knuckle (C) and move the level directly under the rear end of the rear attachment bolt of the lower control arm (B). 8. Measure the distance between the center of the bolt and the top of the level for your second measurement. 9. Average the measurements between the step 6 and step 8. 10. Record the measurement. Z Height Adjustment Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1575 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion bar adjusting arm as needed. 2. For vehicles without torsion bars, replace worn or damaged components as necessary. D Height Measurement 1. Jounce the rear suspension of the vehicle by pushing the vehicle down and lifting up. 2. Allow the vehicle to settle and take a measurement. 3. Measure between the axle bracket and jounce bumper mount bracket as shown in graphic. 4. If any of these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement Alignment: Service and Repair Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull Correction) in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections in order to ensure correct alignment readings: * Inspect for visible damage to the suspension components and replace as necessary. * Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label) and Tire Diagnosis - Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear). * Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Specifications/Tire and Wheel Runout Specifications). * Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis). * Inspect the ball joints for looseness or wear. * Inspect the tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications (See: Specifications/Mechanical Specifications/Steering/System Specifications/Power Steering). * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Suspension Strut and Shock Absorber Testing - On Vehicle (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle). * Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Note: * Record the "Before" and "After" alignment measurements. * When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear toe adjustment first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 1578 Alignment: Service and Repair Front Caster and Camber Adjustment Front Caster and Camber Adjustment Note: Caster measurements are now relative to ground. 1. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Note: Before adjusting the caster and camber angles, jounce the front bumper 3 times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Inspection (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). 2. For an accurate reading, do not push or pull on the tires during the alignment process. 3. Determine the caster angle (2). 4. Determine the positive camber (2) or negative camber (3) angle. 5. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 6. Loosen the upper control arm cam adjustment bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met. When the adjustments are complete, hold Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 1579 the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. Tighten the cam nuts to 190 Nm (140 lb ft). 8. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). When the caster and camber are within specifications, adjust the toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 1580 Alignment: Service and Repair Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment 1. Loosen the jam nut on the inner tie rod (1). 2. Rotate the inner tie rod (2) to the required toe specification setting. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the jam nut (1) on the tie rod and tighten to 75 Nm (55 lb ft). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Service Precautions Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) Fuel Pressure: Testing and Inspection Fuel System Diagnosis (FPCM) Fuel System Diagnosis (FPCM) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for 2 seconds, unless the engine is in Crank or Run. While this voltage is being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure. The fuel system is an electronic returnless on-demand design. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump is contained by the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pump module contains a reverse flow check valve. The check valve maintains fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Reference Information Description and Operation Fuel System Description (See: Powertrain Management/Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH-48027 Digital Pressure Gauge * J 37287 Fuel Line Shut-off Adapter Circuit/System Verification Note: * Repair all fuel system related DTCs before performing this diagnostic, unless instructed here from a DTC diagnostic. * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. * DO NOT perform the Fuel System Diagnosis if the engine coolant temperature is above 60°C (150°F). High fuel pressure readings may result due to hot soak fuel boiling. With the engine OFF, the fuel pressure may increase beyond the pressure relief valves set point of 690 kPa = / -5 % (100 psi ±5 %). 1. Ignition OFF, all accessories OFF, install a CH-48027 . Refer to Fuel Pressure Gauge Installation and Removal (See: Fuel Pressure Gauge Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) > Page 1587 Installation and Removal). 2. Ignition ON, engine OFF, command the fuel pump ON with a scan tool. Verify the fuel pressure is between 345-690 kPa (50-100 psi) with the pump running. 3. Engine ON with the engine idling at normal operating temperature, the Fuel Rail Pressure Sensor parameter should read between 296.4-310.3 kPa (43-45 psi). Circuit/System Testing Note: * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, engine OFF, command the fuel pump ON with a scan tool and observe the fuel pressure gauge while the fuel pump is operating. Verify the fuel pressure is between 345-690 kPa (50-100 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 2. Verify that the fuel pressure, after the fuel pump is turned off, decreases to 500-599 kPa (72-87 psi), and does not decrease more than 34 kPa (5 psi) in 1 minute from that point. ‹› If the fuel pressure stays above 600 kPa (87 psi), replace the fuel pump module. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair ). 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 . 4. Ignition ON, command the fuel pump ON with a scan tool and bleed the air from the CH-48027 . 5. Command the fuel pump ON and then OFF with a scan tool. 6. Close the valve on the J 37287 . 7. Monitor the fuel pressure for 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module. 4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with the CH-48027 . The fuel pressure should not drop off during acceleration, cruise or hard cornering. ‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections 5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) > Page 1588 Fuel Pressure: Testing and Inspection Fuel Pressure Gauge Installation and Removal Fuel Pressure Gauge Installation and Removal Special Tools CH-48027 Digital Pressure Gauge Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions. Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) > Page 1589 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1593 Idle Speed: Testing and Inspection Throttle/Idle Learn Description The engine control module (ECM) learns the airflow through the throttle body to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to throttle body coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned. An engine that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero. The idle may be unstable or a DTC may set if the learned values do not match the actual airflow. Conditions for Running the Throttle Learn Procedure Reset Procedure * DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set. * Ignition ON, engine OFF. * The vehicle speed sensor (VSS) is 0 km/h (0 mph). Learn Procedure * DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set. * The engine speed is between 450-4,000 RPM. * The manifold absolute pressure (MAP) is greater than 5 kPa. * The mass air flow (MAF) is greater than 2 g/s. * The ignition voltage is greater than 10 volts. Throttle Learn Reset Procedure (Performed after the throttle body is cleaned or replaced) 1. Ignition ON, engine OFF, perform the Idle Learn Reset in Module Setup with a scan tool. 2. Start the engine and monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation value should equal 0 percent and the engine should be idling at a normal idle speed. 3. Clear the DTCs and return to the diagnostic that referred you here. Learn Procedure (Performed after the ECM is flashed or replaced) Note: Do NOT perform this procedure if DTCs are set. Refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle). 1. Start and idle the engine for 3 minutes. 2. With a scan tool, monitor the Desired Idle Speed and the actual Engine Speed. 3. The ECM will start to learn the new idle cells and Desired Idle Speed should start to decrease. 4. Ignition OFF for 60 seconds. 5. Start and idle the engine for 3 minutes. 6. After the 3 minute run time the engine should be idling normal. Note: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. ‹› If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles. 7. After the drive cycle, the engine should be idling normally. ‹› If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1594 8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that referred you here. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Resonator Outlet Duct Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct. 3. Remove the radiator inlet hose clamp retainer from the outlet duct. 4. Loosen the air cleaner outlet duct clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 5. Loosen the air cleaner outlet duct clamp (2) at the throttle body. 6. Lift up the air cleaner outlet duct at the resonator tab in order to separate the resonator from the stud on the intake manifold. 7. Remove the air cleaner outlet duct from the throttle body and MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1599 Installation Procedure 1. Install the air cleaner outlet duct to the throttle body and MAF/IAT sensor. Ensure that the resonator tab aligns with the stud on the intake manifold. 2. Push down on the air cleaner outlet duct resonator directly over the resonator tab in order to secure the resonator to the stud on the intake manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 3. Tighten the air cleaner outlet duct clamp (2) at the throttle body to 4 Nm(35 lb in). 4. Tighten the air cleaner outlet duct clamp (1) to 4 Nm(35 lb in) at the MAF/IAT sensor. 5. Install the radiator inlet hose clamp retainer to the outlet duct. 6. Install the PCV line (1) to the air cleaner outlet duct. 7. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief (CH-48027) Special Tools CH-48027 - Digital Pressure Gauge Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1607 * The fuel pipe connections * The hose connections * The areas surrounding the connections Note: If relieving the fuel pressure for the fuel pressure gauge installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Ignition System Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires, Incorrect routing may cause cross firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for any of the following conditions: * Tearing * Piercing * Arcing * Carbon tracking * Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 1614 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 1615 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Ignition System Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1619 Spark Plug: Application and ID Ignition System Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1620 Spark Plug: Testing and Inspection Spark Plug Inspection * Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Powertrain Management/Ignition System/Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling, replace with a colder plug - Pre-ignition causing spark plug and/or engine damage , replace with a hotter plug * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. * Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1621 * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection * Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak ignition coils * Worn ignition wires * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1622 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Brush or using compressed air, blow away any dirt from around the spark plug. 3. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1623 1. Inspect the spark plug gap. Adjust the gap as needed. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). 2. Hand start the spark plug in the corresponding cylinder. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the spark plug to 15 Nm (11 lb ft). 4. Install the spark plug wire to the spark plug. 5. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1627 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gauge at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Inspect the sprockets for proper alignment. The mark on the CMP (1) actuator sprocket should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1635 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1636 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1637 Drive Belt: Diagrams Drive Belt Replacement - Accessory Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1638 Drive Belt: Service Precautions Belt Dressing Caution Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1639 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: * The drive belt * The drive belt tensioner * The drive belt idler pulley * The crankshaft balancer pulley * The accessory drive component mounting brackets * The accessory drive components - The power steering pump - The generator - The A/C compressor - The engine cooling fan - The water pump, if belt driven The drive belt system may use 2 belts. The drive belt (1) is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of different types of rubbers - chloroprene or EPDM - and have different layers or plies containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system has an idler pulley, which is used to add wrap to the adjacent pulleys. A/C Compressor Drive Belt Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1640 The outward appearance of the belt (1) is similar to the current design serpentine belt. The reinforcing cord provides its unique qualities. The belt cord is made of a polyamid material. The polyamid cord is more elastic than the more traditional aramid or polyester cord designs. A tensioner is not needed. Polyamid cord, when combined with a more elastic backing compound, ensures the belt is able to maintain the specified tension within the specified range of usage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt Chirping, Squeal, and Whine Diagnosis Diagnostic Aids * A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. * If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. * A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise. * The drive belts will not cause a whine noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1643 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1644 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1645 Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis Drive Belt Rumbling and Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1646 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1647 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1648 Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis Drive Belt Falls Off and Excessive Wear Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspection of the fasteners can eliminate the possibility that a wrong bolt, nut , spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1649 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Air Conditioning Compressor Belt Replacement (V8) Drive Belt: Service and Repair Air Conditioning Compressor Belt Replacement (V8) Air Conditioning Compressor Belt Replacement (V8) Removal Procedure 1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt Replacement - Accessory). 2. Remove the skid plate. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Cut the belt (1) from air conditioning (A/C) and crankshaft pulleys. Installation Procedure Note: The OEM replacement stretchy belt is packaged with a disposable installation tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Air Conditioning Compressor Belt Replacement (V8) > Page 1652 1. Position the belt behind the rear face of the balancer (1) and off of the A/C pulley (2). 2. Install the belt installation tool (3) onto the balancer. 3. Slide the belt installation tool (1) upward, installing the belt (2) onto the belt installation tool. 4. Slide the belt installation tool downward, positioning the belt onto the A/C pulley, applying light tension to the belt. 5. Position the lower portion of the belt (1) with the ribbed area facing forward. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Air Conditioning Compressor Belt Replacement (V8) > Page 1653 6. Slowly rotate the crankshaft pulley (1) in a clockwise direction while using finger pressure to pull the belt (2) forward. Ensure that the ribbed area of the belt remains facing forward and the belt aligns properly to the A/C pulley. 7. Inspect the drive belt (1) for proper installation and alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Air Conditioning Compressor Belt Replacement (V8) > Page 1654 8. Rotate the balancer (1) and additional 360 degrees to ensure proper belt installation. 9. Install the skid plate. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 10. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt Replacement - Accessory). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Air Conditioning Compressor Belt Replacement (V8) > Page 1655 Drive Belt: Service and Repair Drive Belt Replacement - Accessory Drive Belt Replacement - Accessory Removal Procedure 1. Open the hood. 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 3. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 4. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt. 5. Remove the drive belt (1) from the pulleys and the drive belt tensioner. 6. Slowly release the tension on the drive belt tensioner. 7. Remove the breaker bar and socket and from the drive belt tensioner bolt. 8. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure 1. Route the drive belt (1) around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. 7. Inspect the drive belt for proper installation and alignment. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 9. Start the vehicle and inspect the drive belt for proper operation. 10. Close the hood. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Resonator Outlet Duct Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct. 3. Remove the radiator inlet hose clamp retainer from the outlet duct. 4. Loosen the air cleaner outlet duct clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 5. Loosen the air cleaner outlet duct clamp (2) at the throttle body. 6. Lift up the air cleaner outlet duct at the resonator tab in order to separate the resonator from the stud on the intake manifold. 7. Remove the air cleaner outlet duct from the throttle body and MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1661 Installation Procedure 1. Install the air cleaner outlet duct to the throttle body and MAF/IAT sensor. Ensure that the resonator tab aligns with the stud on the intake manifold. 2. Push down on the air cleaner outlet duct resonator directly over the resonator tab in order to secure the resonator to the stud on the intake manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 3. Tighten the air cleaner outlet duct clamp (2) at the throttle body to 4 Nm(35 lb in). 4. Tighten the air cleaner outlet duct clamp (1) to 4 Nm(35 lb in) at the MAF/IAT sensor. 5. Install the radiator inlet hose clamp retainer to the outlet duct. 6. Install the PCV line (1) to the air cleaner outlet duct. 7. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 1673 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 1674 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 1675 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 1676 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 1682 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 1683 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 1684 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 1685 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Canister Filter: > 09-03-10-008B > Jul > 10 > Wheels/Tires Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Filter - A/T: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Fluid and Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair). 6. Remove the oil pan bolts from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 9. Remove the remaining oil pan bolts. 10. Remove the oil pan and the gasket. 11. Grasp firmly while pulling down with a twisting motion in order to remove the filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1700 12. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: * Clutch material * Bronze slivers indicating bushing wear * Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. 4. Install the oil pan and NEW gasket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1701 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the oil pan bolts. Tighten the bolts alternately and evenly to 11 Nm (97 lb in). 6. Install the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) ( See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair). 7. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 Nm (18 lb ft). 8. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Fluid Level and Condition Check) and Fluid Capacity Specifications (See: Fluids/Fluid A/T/Specifications). 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1702 Fluid Filter - A/T: Service and Repair Allison - Automatic Transmission Automatic Transmission Fluid and Filter Replacement Removal Procedure Note: DO NOT drain the fluid if only the transmission external oil filter is being replaced. 1. Remove the drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. 2. Inspect the drained fluid. Refer to Transmission Fluid Level and Condition Check (). Note: Use a standard strap-type filter wrench to remove the transmission external oil filter. 3. Remove the filter (4) by rotating in the counterclockwise direction. 4. Remove the magnet (2) from the filter adapter (1) in the converter housing or from the top of the transmission external oil filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Install the magnet (2) onto the filter adapter (1) which is in the converter housing. 2. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 3. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Caution: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 4. Turn the filter ONE FULL TURN ONLY after gasket contact. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the drain plug (6) and drain plug seal (5). Tighten the drain plug to 35 Nm (26 lb ft). 6. Refill Transmission with DEXRON(R)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications (See: Fluids/Fluid A/T/Specifications). Note: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 1703 7. Cycle the ignition until Drive or Reverse range is attained. Note: Fluid remains in the external circuits and transmission cavities after draining the transmission. 8. Check the transmission fluid level. Refer to Transmission Fluid Level and Condition Check (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief (CH-48027) Special Tools CH-48027 - Digital Pressure Gauge Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1708 * The fuel pipe connections * The hose connections * The areas surrounding the connections Note: If relieving the fuel pressure for the fuel pressure gauge installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up Oil Filter: Customer Interest Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 1717 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up Oil Filter: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 1723 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 07-06-01-016B > Jul > 09 > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: All Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Filter: > 07-06-01-016B > Jul > 09 > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: All Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1733 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to drain completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and inspect the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1734 10. Position the drain pan under the oil filter (437). 11. Remove the oil filter. 12. Ensure that the oil filter gasket is still on the old filter if not, remove the oil filter gasket from the oil pan. Installation Procedure 1. Apply clean engine oil to the NEW oil filter seal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW oil filter (437) and tighten to 30 Nm (22 lb ft). 3. Tighten the oil pan drain plug (430) to 25 Nm (18 lb ft). 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities (See: Specifications) and Fluid and Lubricant Recommendations Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1735 (USA and Canada) (See: ). 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) Coolant Line/Hose: Service and Repair Engine Coolant Air Bleed Pipe Replacement (without AFM) Engine Coolant Air Bleed Pipe Replacement (without AFM) Removal Procedure 1. If replacing the rear coolant air bleed covers, remove the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Otherwise proceed to the next step. 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 3. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 4. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 5. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 1741 6. Remove the coolant air bleed pipe bolts (309) (intake manifold shown removed for clarity). 7. Remove the coolant air bleed pipe (307) and seals (308). 8. Remove the coolant air bleed cover bolts (312), if required. 9. Remove the coolant air bleed covers (313) and seals (308), if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 1742 10. Remove the seals (308) from the coolant air bleed pipe and/or covers. 11. Discard the seals. Installation Procedure Note: Position the O-ring seal (308) onto the nipple portion of the pipe. 1. Install the seals onto the coolant air bleed pipe and/or covers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 1743 2. Install the coolant air bleed pipe (307) and seals (308) onto the cylinder heads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the coolant air bleed pipe bolts (309). Tighten the bolts to 12 Nm (106 lb in). 4. Install the coolant air bleed covers (313) and seals (308), if required. 5. Install the coolant air bleed cover bolts (312), if required. Tighten the bolts to 12 Nm (106 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 1744 6. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 7. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 10. If the rear coolant air bleed covers were replaced, install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 1745 Coolant Line/Hose: Service and Repair Engine Coolant Air Bleed Pipe Replacement (with AFM) Engine Coolant Air Bleed Pipe Replacement (with AFM) Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 3. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 4. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting. 5. Remove the coolant air bleed pipe bolts (309) (intake manifold shown removed for clarity). 6. Remove the coolant air bleed pipe (307) and seals (308). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 1746 7. Remove the coolant air bleed cover bolts (312), if required. 8. Discard the seals. Installation Procedure Note: Position the O-ring seal (308) onto the nipple portion of the pipe. 1. Install the seals onto the coolant air bleed pipe and/or covers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 1747 2. Install the coolant air bleed pipe (307) and seals (308) onto the cylinder heads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the coolant air bleed pipe bolts (309). Tighten the bolts to 12 Nm (106 lb in). 4. Install the coolant air bleed covers (313) and seals (308), if required. 5. Install the coolant air bleed cover bolts (312), if required. Tighten the bolts to 12 Nm (106 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 1748 6. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 7. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 10. If the rear coolant air bleed covers were replaced, install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) Heater Hose: Service and Repair Heater Inlet Hose Replacement (Non-HP2) Heater Inlet Hose Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. Quick Connect Fittings 5. Pull the connection apart. 6. Remove the inlet heater hose from the water pump. 7. Remove the inlet heater hose. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 1753 Installation Procedure 1. Install the inlet heater hose. 2. Install the inlet heater hose to the water pump. 3. Connect the heater hose to the heater core. Important: Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hoses to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 1754 Heater Hose: Service and Repair Heater Outlet Hose Replacement (Non-HP2) Heater Outlet Hose Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. Quick Connect Fittings 5. Pull the connection apart. 6. Remove the outlet heater hose from the water pump. 7. Reposition the outlet heater hose clamp at the surge tank. 8. Remove the outlet heater hose from the surge tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 1755 9. Remove the outlet heater hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Important: Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Pull the heater outlet hose to ensure the connection. 7. Install the heater and surge tank hoses to the mounting clip. 8. Install the air intake tube. 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement Hose/Line HVAC: Service and Repair Discharge Hose Replacement Discharge Hose Replacement (LY2, LMF, L76 and L92) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Fluids/Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Heating and Air Conditioning/Service and Repair). 2. Remove the discharge hose mounting bolt (2) from the A/C compressor. 3. Remove the discharge hose (1) from the A/C compressor. 4. Remove the upper radiator baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 5. Remove the discharge hose nut from the condenser. 6. Remove the discharge hose from the condenser. 7. Disconnect the electrical connector from the A/C recirculation switch. 8. Remove the discharge hose from the vehicle. 9. Discard all of the used sealing washers. Cap the system openings. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 1760 1. Install the discharge hose (1) to the vehicle. 2. Install the discharge hose to the condenser using new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Heating and Air Conditioning/Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the discharge hose nut to the condenser and tighten to 16 Nm (12 lb ft). 4. Install the upper air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 5. Connect the electrical connector to the A/C recirculation switch. 6. Install the discharge hose (1) to the A/C compressor using new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Heating and Air Conditioning/Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 7. Install the discharge hose mounting bolt and tighten to 16 Nm (12 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Fluids/Refrigerant/Service and Repair )Refrigerant Recovery and Recharging (HP2) (See: Heating and Air Conditioning/Service and Repair). 9. Leak test the fittings of the component using the J 39400-A . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 1761 Hose/Line HVAC: Service and Repair Suction Hose Replacement Suction Hose Replacement (LY2, LMF, L76 and L92) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 1762 Hose/Line HVAC: Service and Repair Air Conditioning Evaporator Tube Replacement (Non-HP2) Air Conditioning Evaporator Tube Replacement (Non-HP2) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Fluids/Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Heating and Air Conditioning/Service and Repair). 2. Remove the upper radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Filters/Air Cleaner Housing/Service and Repair). 4. Remove the surge tank hold down nut and bolt and position aside. Note: Do not open cooling system. 5. Remove the evaporator tube nut from the evaporator. 6. Disconnect the evaporator tube from the evaporator. 7. Remove the evaporator tube nut from the auxiliary A/C tube, if equipped. 8. Disconnect the evaporator tube from the auxiliary A/C tube, if equipped. 9. Remove the evaporator tube nut from the condenser. 10. Disconnect the evaporator tube from the condenser. 11. Remove the evaporator tube from the vehicle. 12. Discard all of the used sealing washers. Cap all of the open connections. Installation Procedure 1. Connect the evaporator tube to the condenser using new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Heating and Air Conditioning/Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 1763 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the evaporator tube nut to the condenser and tighten to 16 Nm (12 lb ft). 3. Connect the evaporator tube to the auxiliary A/C tube using new sealing washers, if equipped. Refer to Air Conditioning System Seal Replacement (See: Heating and Air Conditioning/Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 4. Install the evaporator tube nut to the auxiliary A/C tube, if equipped, and tighten to 16 Nm (12 lb ft). 5. Install the evaporator tube to the evaporator. 6. Install the evaporator tube nut to the evaporator and tighten to 16 Nm (12 lb ft). 7. Install the surge tank hold down nut and bolt and position aside. 8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Filters/Air Cleaner Housing/Service and Repair). 9. Install the upper radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Fluids/Refrigerant/Service and Repair )Refrigerant Recovery and Recharging (HP2) (See: Heating and Air Conditioning/Service and Repair). 11. Leak test the fittings of the components using the J 39400-A . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 07-02-32-002J > Jul > 10 > Steering/Suspension - Power Steering Fluid Leaking Power Steering Line/Hose: All Technical Service Bulletins Steering/Suspension - Power Steering Fluid Leaking ENGINEERING INFORMATION Bulletin No.: 07-02-32-002J Date: July 23, 2010 Subject: EI07082 - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly (Engineering Recommendations / Engineering Information Closed) Models: 2008-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 GMC Denali, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series Only and Excluding Hybrids Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-02-32-002I (Section 02 - Steering). Condition Some customers may comment on a fluid leak. Upon investigation, the technician may find fluid leaking from the power steering system. Please use the following information to assist in diagnosis. Diagnostic Information Important All potential leaks should be completely cleaned and identified before attempting to repair or replace any power steering components. 1. Start diagnosis by inspecting the fluid level in the power steering reservoir. If the fluid level is NOT low, a careful analysis of the condition is necessary as it may involve a different type of fluid leak. 2. Visually inspect the components where the fluid has accumulated. 3. Completely clean off any fluid residue from the suspect components. 4. Apply tracing powder to the suspect components. This is an effective way to determine the source of a leak. As an alternative, fluorescent dye (such as Kent Moore J 28431-6) may be added to the power steering fluid. 5. Start the vehicle and allow the power steering system to reach normal operating temperatures. 6. Turn the steering wheel to the stops in each direction while bumping the steering wheel against the stops 3-4 times. This will build maximum steering system pressure and help identify the source of the leak if present. 7. Determine the source of the leak. 8. If a repeatable leak is found, refer to the following tables to determine the proper corrective action needed. Repairable Leaks Non- Repairable Leaks *If fluid is observed at the adjuster plug during the initial visual inspection, then refer to the following: - Seepage at the adjuster plug may not necessarily indicate an active leak. Power steering fluid is used during the manufacturing of the gear/rack. The fluid used at assembly is pushed into the pinion area during assembly. The adjuster plug and the area below the pinion are not positively Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 07-02-32-002J > Jul > 10 > Steering/Suspension - Power Steering Fluid Leaking > Page 1772 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 07-02-32-002J > Jul > 10 > Steering/Suspension Power Steering Fluid Leaking Power Steering Line/Hose: Customer Interest Steering/Suspension - Power Steering Fluid Leaking ENGINEERING INFORMATION Bulletin No.: 07-02-32-002J Date: July 23, 2010 Subject: EI07082 - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly (Engineering Recommendations / Engineering Information Closed) Models: 2008-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 GMC Denali, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series Only and Excluding Hybrids Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-02-32-002I (Section 02 - Steering). Condition Some customers may comment on a fluid leak. Upon investigation, the technician may find fluid leaking from the power steering system. Please use the following information to assist in diagnosis. Diagnostic Information Important All potential leaks should be completely cleaned and identified before attempting to repair or replace any power steering components. 1. Start diagnosis by inspecting the fluid level in the power steering reservoir. If the fluid level is NOT low, a careful analysis of the condition is necessary as it may involve a different type of fluid leak. 2. Visually inspect the components where the fluid has accumulated. 3. Completely clean off any fluid residue from the suspect components. 4. Apply tracing powder to the suspect components. This is an effective way to determine the source of a leak. As an alternative, fluorescent dye (such as Kent Moore J 28431-6) may be added to the power steering fluid. 5. Start the vehicle and allow the power steering system to reach normal operating temperatures. 6. Turn the steering wheel to the stops in each direction while bumping the steering wheel against the stops 3-4 times. This will build maximum steering system pressure and help identify the source of the leak if present. 7. Determine the source of the leak. 8. If a repeatable leak is found, refer to the following tables to determine the proper corrective action needed. Repairable Leaks Non- Repairable Leaks *If fluid is observed at the adjuster plug during the initial visual inspection, then refer to the following: - Seepage at the adjuster plug may not necessarily indicate an active leak. Power steering fluid is used during the manufacturing of the gear/rack. The fluid used at assembly is pushed into the pinion area during assembly. The adjuster plug and the area below the pinion are not positively Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 07-02-32-002J > Jul > 10 > Steering/Suspension Power Steering Fluid Leaking > Page 1778 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 1779 Power Steering Line/Hose: Service Precautions Power Steering Hose Disconnected Caution Caution: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid and damage to the system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Install drain pans under the vehicle as needed. Caution: Refer to Power Steering Hose Disconnected Caution (See: Service Precautions). Note: Note the routing of the power steering gear inlet hose before removal. It MUST be routed correctly upon installation. 2. Remove the power steering gear inlet hose (2) from the power brake booster (1). 3. Remove the power steering gear inlet hose (2) from the power steering gear. 4. Remove the power steering gear inlet hose (2) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 1782 Caution: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Note: The power steering gear inlet hose cannot be routed between the brake lines and the power brake booster during installation. 1. Route the power steering gear inlet hose in the same position it was in prior to removal. 2. Install the power steering gear inlet hose (2) to the power brake booster (1) and hand tighten only. Rotate the power steering gear inlet hose clockwise until the it contacts the power brake booster housing and then hold it in position while tightening it to the fitting specification. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the power steering gear inlet hose (2) to the power steering gear. Tighten the fittings to 32 Nm (24 lb ft). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 1783 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 1784 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Place drain pans under the vehicle as needed. Caution: Refer to Power Steering Hose Disconnected Caution (See: Service Precautions). 2. Disconnect the power steering fluid cooler hose clamp and hose (3) from the steering gear (2). 3. Remove the power steering gear outlet pipe (1) from the steering gear (2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 1785 1. Install the power steering gear outlet pipe (1) to the steering gear (2). 2. Connect the power steering fluid cooler hose (3) and hose clamp to the steering gear (2). 3. Clean any excess fluid from the vehicle and remove the drain pans. 4. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair) . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 1786 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 1787 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Install drain pans under the vehicle as needed. Caution: Refer to Power Steering Hose Disconnected Caution (See: Service Precautions). Note: Note the routing of the power steering gear inlet hose before removal. It MUST be routed correctly upon installation. 2. Remove the power steering gear inlet hose (2) from the power brake booster (1). 3. Remove the power steering gear inlet hose (2) from the power steering gear. 4. Remove the power steering gear inlet hose (2) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 1788 Caution: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Note: The power steering gear inlet hose cannot be routed between the brake lines and the power brake booster during installation. 1. Route the power steering gear inlet hose in the same position it was in prior to removal. 2. Install the power steering gear inlet hose (2) to the power brake booster (1) and hand tighten only. Rotate the power steering gear inlet hose clockwise until the it contacts the power brake booster housing and then hold it in position while tightening it to the fitting specification. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the power steering gear inlet hose (2) to the power steering gear. Tighten the fittings to 32 Nm (24 lb ft). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair). Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 1789 Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Place drain pans under the vehicle as needed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 1790 Caution: Refer to Power Steering Hose Disconnected Caution (See: Service Precautions). 2. Disconnect the power steering fluid cooler hose clamp and hose (3) from the steering gear (2). 3. Remove the power steering gear outlet pipe (1) from the steering gear (2). Installation Procedure 1. Install the power steering gear outlet pipe (1) to the steering gear (2). 2. Connect the power steering fluid cooler hose (3) and hose clamp to the steering gear (2). 3. Clean any excess fluid from the vehicle and remove the drain pans. 4. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair) . Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 1791 Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Diesel) Power Steering Gear Outlet Pipe/Hose Replacement (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 1792 Removal Procedure 1. Remove as much power steering fluid from the power steering fluid reservoir as possible. 2. Place drain pans under the vehicle as needed. 3. Compress the power steering gear outlet hose clamp (2). 4. Disconnect the power steering gear outlet hose (1) from the power steering pump assembly (3). 5. Disconnect the power steering gear outlet hose (2) from the steering gear (1). 6. Remove the power steering gear outlet hose (1) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 1793 1. Install the power steering gear outlet hose (1) to the vehicle. 2. Connect the power steering gear outlet hose (2) to the steering gear (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Compress the power steering gear outlet hose clamp (2). 4. Connect the power steering gear outlet hose (1) to the power steering pump assembly (3). Tighten the fitting to 32 Nm (24 lb ft). 5. Clean any excessive power steering fluid from the vehicle and remove the drain pans. 6. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair). Power Brake Booster Inlet Hose Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 1794 Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 2. Place drain pans under the vehicle as needed. 3. Remove as much power steering fluid from the power steering fluid reservoir as possible. Caution: Refer to Power Steering Hose Disconnected Caution (See: Service Precautions). 4. Disconnect the power brake booster inlet hose from the power steering pump (3). 5. Disconnect the power brake booster inlet hose (1) from the power brake booster (2). 6. Remove the power brake booster inlet hose (1) from the vehicle. Installation Procedure Caution: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. 1. Install the power brake booster inlet hose (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Start both power brake booster inlet hose fittings by hand before finalizing torques. 2. Connect the power brake booster inlet hose (1) to the power brake booster (2). Tighten the fitting to 32 Nm (24 lb ft). 3. Connect the power brake booster inlet hose (1) to the power steering pump (3). Tighten the fitting to 32 Nm (24 lb ft). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 6. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 1795 Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure 1. Place drain pans under the vehicle as needed. 2. Remove as much power steering fluid from the power steering fluid reservoir as possible. Caution: Refer to Power Steering Hose Disconnected Caution (See: Service Precautions). 3. Disconnect the power brake booster outlet hose (1) from the power brake booster (2). 4. Disconnect the power brake booster outlet hose (1) from the power steering fluid reservoir (3). 5. Remove the power brake booster outlet hose (1) from the vehicle. Installation Procedure Caution: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. 1. Install the power brake booster outlet hose (1) to the vehicle. 2. Connect the power brake booster outlet hose (1) to the power steering fluid reservoir (3). 3. Connect the power brake booster outlet hose (1) to the power brake booster (2). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement Radiator Hose: Service and Repair Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement (Non-HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 1800 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement (Non-HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 1801 Radiator Hose: Service and Repair Radiator Hose Quick Connect Fitting Radiator Hose Quick Connect Fitting Removal Procedure 1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 2. Rotate the retaining ring (3) around the quick connector until the retaining ring is out of position and can be completely removed. 3. Remove the radiator outlet hose (2) from the quick connector fitting at the radiator (1). Installation Procedure Note: Do not install the retaining ring (3) onto the fitting by pushing the retaining ring down over the fitting. 1. Hook one of the open ends of the retaining ring (3) in one of the slots in the quick connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 1802 2. Rotate the retaining ring (3) around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 3. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 4. Install the radiator outlet hose (2) onto the radiator quick connector fitting until a click is heard or felt. Pull back on the radiator outlet hose (2) to ensure a proper connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic Brake System: DOT 3 Hydraulic Brake Fluid (GM Part No. U.S. 12377967, in Canada 89021320). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications HYDRAULIC CLUTCH FLUID GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM 1500 Series ........................................................................................................ .............................................................................. 16.8 quarts (15.9 liters) 2500, 3500 Series .......... .............................................................................................................................................................. .... 16.4 quarts (15.5 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1814 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in the vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in the vehicle for five years or 240 000 km (150,000 miles), whichever occurs first. The following explains the cooling system and how to check and add coolant when it is low. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. If using this mixture, nothing else needs to be added. This mixture: Gives freezing protection down to -34°F (-37°C). Gives boiling protection up to 265°F (129°C). Protects against rust and corrosion. Will not damage aluminum parts. Helps keep the proper engine temperature. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Fluid - M/T: > 09-04-19-002A > Feb > 11 > Drivetrain Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest for Differential Fluid - M/T: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Fluid - Transfer Case: > 06-08-61-003F > Apr > 11 > Body/Frame - Underbody Pop/Clunk When Turning Body / Frame Mount Bushing: All Technical Service Bulletins Body/Frame - Underbody Pop/Clunk When Turning TECHNICAL Bulletin No.: 06-08-61-003F Date: April 12, 2011 Subject: Underbody Pop or Clunk Type Noise While Turning or Driving on Uneven Road Surfaces (Install Body Mount Insulator) Models: 2004-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2004-2012 Chevrolet Avalanche, Silverado (Classic), Silverado, Suburban, Tahoe 2004-2012 GMC Sierra (Classic), Sierra Denali (Classic), Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-61-003E (Section 08 - Body and Accessories). Condition Some customers may comment on a pop or clunk type noise while turning or driving on uneven road surfaces. This noise can be heard and/or felt at either the driver's or front passenger floor pan area. Cause Under certain conditions, normal movement between the frame and the #1, #2 or #3 body mounts may cause this noise to occur. Diagnosis 1. If the vehicle is equipped with aftermarket (non-GM Accessory) running boards or the running board is mounted using the body mount bolt, remove the running boards prior to test driving the vehicle. This will eliminate the running boards as the possible cause of the noise. 2. Install the J-39570 Chassis Ears to the frame rail at or near the body mounts. 3. Test drive the vehicle to identify which mount is suspect. Correction Install an insulator at the suspect mount(s). The insulator should be installed between the upper portion of the body mount and the frame bracket. The #1 mount is the mount located just under the A-pillar. The #2 mount is the mount located just under the B-pillar. The #3 mount is the mount located just under the C-pillar. Use the procedure listed below. 1. Raise the vehicle on the hoist. It is recommended to use a four-post lift or strap the vehicle frame to the hoist arms. 2. For the left side mounts only, remove the intermediate park brake cable. Perform the following steps: 1. Remove the nut from the park brake equalizer. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 3. Remove all of the body mount bolts on the side being repaired. 4. Properly support the body at the body mount area. Caution When you remove the body mount, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Fluid - Transfer Case: > 06-08-61-003F > Apr > 11 > Body/Frame - Underbody Pop/Clunk When Turning > Page 1846 5. Lower the chassis accordingly in order to remove the upper portion of the body mount. 6. Install the new insulator to the bottom of the top portion of the body mount. The picture shows the insulator (1) location after the body mount is reassembled. 7. Install the body mount to the frame bracket. 8. Perform the following procedure before installing the bolts. 1. Clean the bolt threads of all the original thread locking compound. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker, GM P/N 89021297 (In Canada, use P/N 10953488). 9. Install the body mount bolts. Tighten For 2003, 2004 and 2005 model year, tighten the bolts to 85 Nm (63 lb ft). Tighten For 2006-2012 model year, tighten the bolts to 100 Nm (74 lb ft). 10. Reinstall the intermediate park brake cable (left side only). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Fluid - Transfer Case: > 10-08-61-001A > Feb > 11 > Body - Body Mount Bolt Stripped or Will Not Loosen Body / Frame Mount Bushing: All Technical Service Bulletins Body - Body Mount Bolt Stripped or Will Not Loosen INFORMATION Bulletin No.: 10-08-61-001A Date: February 16, 2011 Subject: Information on Body Mount Bolt Stripped or Will Not Loosen Models: 2010-2011 Chevrolet Silverado 2010-2011 GMC Sierra Supercede: This bulletin is being revised to add Warranty Information. Please discard Corporate Bulletin Number 10-08-61-001 (Section 08 - Body and Accessories). The purpose of this bulletin is to provide guidance to GM dealers when performing repairs that involve the removal of the body mount bolts. Technicians may discover that one of the cab mount bolts won't loosen from the vehicle. The bolt may act like the nut is cross-threaded or no longer secured to the floorpan of the vehicle. The cab mounted cage nut may have bent or broken loose allowing the nut to spin. If the nut is allowed to spin, it may prevent the bolt from loosening. The front cab mount nuts are welded to the body structure and are not involved with this bulletin. The cage nut assembly must be accessed from inside of the vehicle if this condition occurs. Some of the cage nuts have rectangular access plates in the floor of the passenger compartment. These plates are located above the affected bolt. On extended cab vehicles it is necessary to create access holes in the rear floor area to reach the rear cage nut. Creating Access Hole (Extended Cab Vehicles Only) Use the following steps to create an access hole in the rear floor area of extended cab vehicles. This procedure only applies to the rear set of mounting bolts. Note This procedure below is for the left side of the vehicle. The procedure and measurements are the same for both the left and right side procedures. 1. Remove the seat located above the affected bolt. Refer to Rear Seat Replacement in SI. 2. Partially remove (pull back) the floor covering (carpet) to expose the seat mounting stud area of the floor. 3. Apply masking tape to the repair area as shown. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Fluid - Transfer Case: > 10-08-61-001A > Feb > 11 > Body - Body Mount Bolt Stripped or Will Not Loosen > Page 1851 4. Using a straight edge, create a line along the inboard side of the seat mounting studs as shown. 5. Measure and mark as shown (A), 10 mm (3/8 in). 6. Find the center point between the two mounting studs as shown. Create a second mark as shown. 7. Use a center punch to create a mark in the sheet metal. 8. Using a 1-1/2 in. hole saw, create an access hole as shown. 9. Service the cab mounting bolt and nut as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Fluid - Transfer Case: > 10-08-61-001A > Feb > 11 > Body - Body Mount Bolt Stripped or Will Not Loosen > Page 1852 10. Coat the perimeter of the access hole with RTV Silicone Sealant, GM P/N 12378521 (in Canada, 88901148) or equivalent, to seal the bare edge of the metal. 11. Install the round body plug, GM P/N 15908858. Ensure that the plug is sealed with the silicone sealant. 12. Reinstall the floor covering and seat. Cage Nut Access Using Rectangular Service Plug Rectangular service holes have been provided in the floor of the cab to access the cage nut in all other cab mounting bolt locations. The service hole is directly above the cab mount bolt. Use the following steps to remove and replace the service plugs that cover the service hole. 1. Remove the seat located above the affected bolt. Refer to SI for the applicable seat removal steps. 2. Remove the sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement in SI. 3. Partially remove (pull back) the floor covering (carpet) to expose the rectangular service plug. 4. Using a gasket scraper or similar tool, pry off and discard the rectangular floor plug. 5. Service the cab mounting bolt and nut as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Fluid - Transfer Case: > 10-08-61-001A > Feb > 11 > Body - Body Mount Bolt Stripped or Will Not Loosen > Page 1853 6. Coat the perimeter of the access hole with RTV Silicone Sealant, GM P/N 12378521 (in Canada, 88901148) or equivalent, to seal the bare edge of the metal. 7. Install the rectangular body plug, GM P/N 15040085. Ensure that the plug is sealed with the silicone sealant. 8. Reinstall the floor covering, sill trim and seat. Parts Information Warranty Information In most cases, this bulletin information will be used when replacing a body mount and should be claimed under labor code E1095 Drivetrain and Front Suspension Frame Insulator Replacement. If this repair is performed while repairing something different, use the labor code associated with that repair. - Incremental time for this repair should be claimed using Other Labor Hours (OLH). - The recommended OLH for this repair is 0.3-0.5 hr per bolt. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Fluid - Transfer Case: > 06-08-61-003F > Apr > 11 > Body/Frame - Underbody Pop/Clunk When Turning > Page 1859 5. Lower the chassis accordingly in order to remove the upper portion of the body mount. 6. Install the new insulator to the bottom of the top portion of the body mount. The picture shows the insulator (1) location after the body mount is reassembled. 7. Install the body mount to the frame bracket. 8. Perform the following procedure before installing the bolts. 1. Clean the bolt threads of all the original thread locking compound. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker, GM P/N 89021297 (In Canada, use P/N 10953488). 9. Install the body mount bolts. Tighten For 2003, 2004 and 2005 model year, tighten the bolts to 85 Nm (63 lb ft). Tighten For 2006-2012 model year, tighten the bolts to 100 Nm (74 lb ft). 10. Reinstall the intermediate park brake cable (left side only). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Fluid - Transfer Case: > 10-08-61-001A > Feb > 11 > Body - Body Mount Bolt Stripped or Will Not Loosen > Page 1864 4. Using a straight edge, create a line along the inboard side of the seat mounting studs as shown. 5. Measure and mark as shown (A), 10 mm (3/8 in). 6. Find the center point between the two mounting studs as shown. Create a second mark as shown. 7. Use a center punch to create a mark in the sheet metal. 8. Using a 1-1/2 in. hole saw, create an access hole as shown. 9. Service the cab mounting bolt and nut as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Fluid - Transfer Case: > 10-08-61-001A > Feb > 11 > Body - Body Mount Bolt Stripped or Will Not Loosen > Page 1865 10. Coat the perimeter of the access hole with RTV Silicone Sealant, GM P/N 12378521 (in Canada, 88901148) or equivalent, to seal the bare edge of the metal. 11. Install the round body plug, GM P/N 15908858. Ensure that the plug is sealed with the silicone sealant. 12. Reinstall the floor covering and seat. Cage Nut Access Using Rectangular Service Plug Rectangular service holes have been provided in the floor of the cab to access the cage nut in all other cab mounting bolt locations. The service hole is directly above the cab mount bolt. Use the following steps to remove and replace the service plugs that cover the service hole. 1. Remove the seat located above the affected bolt. Refer to SI for the applicable seat removal steps. 2. Remove the sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement in SI. 3. Partially remove (pull back) the floor covering (carpet) to expose the rectangular service plug. 4. Using a gasket scraper or similar tool, pry off and discard the rectangular floor plug. 5. Service the cab mounting bolt and nut as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Fluid - Transfer Case: > 10-08-61-001A > Feb > 11 > Body - Body Mount Bolt Stripped or Will Not Loosen > Page 1866 6. Coat the perimeter of the access hole with RTV Silicone Sealant, GM P/N 12378521 (in Canada, 88901148) or equivalent, to seal the bare edge of the metal. 7. Install the rectangular body plug, GM P/N 15040085. Ensure that the plug is sealed with the silicone sealant. 8. Reinstall the floor covering, sill trim and seat. Parts Information Warranty Information In most cases, this bulletin information will be used when replacing a body mount and should be claimed under labor code E1095 Drivetrain and Front Suspension Frame Insulator Replacement. If this repair is performed while repairing something different, use the labor code associated with that repair. - Incremental time for this repair should be claimed using Other Labor Hours (OLH). - The recommended OLH for this repair is 0.3-0.5 hr per bolt. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information > Page 1871 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications AUTOMATIC TRANSMISSION FLUID CAPACITY 4L60-E / 4L65-E / 4L70-E Automatic Transmission Pan Removal ...................................................... ................................................................................................................................... 4.7 liters (5.0 quarts) Overhaul .................................................................................................................................. ......................................................... 10.6 liters (11.0 quarts) 300 mm Torque Converter Approximate Dry Fill ............................................................................................................................ ................................................................ 11.50 liters (12.1 quarts) 6L80 AUTOMATIC TRANSMISSION Pan Removal ........................................................................... .............................................................................................................. 5.7 liters (6.0 quarts) Overhaul .............................................................................................................................................. ............................................... 9.9 liters (10.5 quarts) Complete Trans System .................................. .................................................................................................................................. 11.7 liters (12.4 quarts) 6L90 AUTOMATIC TRANSMISSION Pan Removal ........................................................................... .............................................................................................................. 6.0 liters (6.3 quarts) Overhaul .............................................................................................................................................. ............................................... 9.9 liters (10.5 quarts) Complete Trans System .................................. .................................................................................................................................. 11.7 liters (12.4 quarts) 2ML70 AUTOMATIC TRANSMISSION Drain Plug Only ..................................................................... ........................................................................................................... 9.93 liters (10.5 quarts) Drop Pan and Filter ...................................................................................................................................... ................................... 10.88 liters (11.5 quarts) Dry Transmission (Empty) .............................................................................................................................................................. 12.30 liters (13.0 quarts) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1874 Fluid - A/T: Fluid Type Specifications Automatic Transmission DEXRON-VI Automatic Transmission Fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1875 Fluid - A/T: Service and Repair Automatic Transmission Fluid and Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair). 6. Remove the oil pan bolts from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 9. Remove the remaining oil pan bolts. 10. Remove the oil pan and the gasket. 11. Grasp firmly while pulling down with a twisting motion in order to remove the filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1876 12. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: * Clutch material * Bronze slivers indicating bushing wear * Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. 4. Install the oil pan and NEW gasket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1877 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the oil pan bolts. Tighten the bolts alternately and evenly to 11 Nm (97 lb in). 6. Install the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) ( See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair). 7. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 Nm (18 lb ft). 8. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Fluid Level and Condition Check) and Fluid Capacity Specifications (See: Specifications). 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications MANUAL TRANSMISSION FLUID CAPACITY TREMEC 5-SPEED (RPO M96) .......................................................................................................................................................... 3.5 liters (3.7 quarts) TREMEC 5-SPEED (RPO TZ0) .......................................................................................................................................................... 4.4 liters (4.6 quarts) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1882 Fluid - M/T: Fluid Type Specifications MANUAL TRANSMISSION FLUID TYPE TREMEC 5-SPEED (M96) ............................................................................................................................................. 5W-30 Synthetic Oil P/N ET-M99 TREMEC 5-SPEED (TZ0) .............................................................................................................................................. 1874 MTX Fluid 12550 ET-M81 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission Fluid - M/T: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 3. Remove the oil fill plug (1). 4. Remove the oil drain plug (2). 5. Remove any old sealant from the transmission housing. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 1885 1. Apply a thin bead of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain plug threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the oil drain plug (2). Tighten the plug to 37 Nm (27 lb ft). 3. Fill the transmission with the proper fluid to just below the bottom of the fill plug hole. 4. Apply a thin bead of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil fill plug threads. 5. Install the oil fill plug (1). Tighten the plug to 37 Nm (27 lb ft). 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 1886 Fluid - M/T: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Transmission Fluid Replacement Special Tools J 36511 Oil Fill/Drain Plug Hex Bit (17 mm) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Using J 36511 remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Using J 36511 remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 1887 Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Using J 36511 install the oil drain plug. Tighten the plug to 30 Nm (22 lb ft). 3. Remove and drain the drain pan used to catch the used transmission fluid. 4. Fill the transmission to just below the bottom of the fill plug hole. Refer to Lubrication Specifications (See: Specifications/Mechanical Specifications/Manual Transmission/Transaxle/Tremec 5-Speed (TZ0) - Manual Transmission/Lubrication Specifications). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 1888 5. Using J 36511 install the oil fill plug. Tighten the plug to 30 Nm (22 lb ft). 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications DRIVE AXLE FLUID CAPACITIES FRONT AXLE 1000 Series (8.25") ...................................................................................................... ..................................................................... 1.43 liters (1.51 quarts) 2000 Series (9.25") .................. ......................................................................................................................................................... 1.73 liters (1.83 quarts) REAR AXLE 1000 Series without RPO AXN (8.6") .............................................................................................................................................. 2.03 liters (2.15 quarts) 1000 Series with RPO AXN (9.5"LD) ................................................................................................................................................ 2.6 liters (2.75 quarts) 2000 Series (9.5"HD) ............................................................................................ ............................................................................. 2.6 liters (2.75 quarts) 2000 Series with RPO LY6 (10.5") .................................................................................................................................................... 2.6 liters (2.75 quarts) 2000 Series with RPO LMM (11.5") .................................................................................................................................................. 3.0 liters (3.17 quarts) 3000 Series (11.5") ................................................................................................ ............................................................................. 3.0 liters (3.17 quarts) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1893 Fluid - Differential: Fluid Type Specifications FRONT AXLE (1500 SERIES) SAE 80W-90 Axle Lubricant (GM Part No. U.S. 89021671, in Canada 89021672). FRONT AXLE (1500 HD, 2500 HD, and 3500 HD SERIES) SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. REAR AXLE SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures Fluid - Differential: Procedures Front Drive Axle Front Axle Lubricant Level Inspection (9.25 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Clean the area around the front axle fill plug. 5. Remove the front axle fill plug (1). 6. Inspect the oil level. The 9.25 inch axle the oil level should be between 0-6 mm (0-0.25 in) below the fill plug opening. 7. If the level is low, add oil until the level is between 0-6 mm (0-0.25 in) for the 9.25 inch axle. Use the correct fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) Note: All axle assemblies are filled by volume of fluid during production. They are not filled to reach a certain level. When checking the fluid level on any axle, variations in the readings can be caused by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle has just been driven before checking the fluid level, it may appear lower than normal because the fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level than a vehicle that has been stationary for an hour or two. Remember that the rear axle assembly must be supported to get a true reading. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Ensure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 1896 5. Remove the rear axle fill plug. 6. Inspect the lubricant level: The lubricant level should be between 1-19 mm (0.04-0.75 in) below the fill plug opening for the 8.6 inch axle. The lubricant level should be between 15-40 mm (0.59-1.57 in) below the fill plug opening for the 9.5 inch LD axle. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: ). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (11.5 Inch Axle) Rear Axle Lubricant Level Inspection (11.5 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 1897 The lubricant level should be between 17-21 mm (0.6-0.8 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is between 17-21 mm (0.6-0.8 in) below the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: ). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug and gasket. Tighten the rear axle fill plug to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (10.5 Inch Axle) Rear Axle Lubricant Level Inspection (10.5 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: ). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 lb ft). 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 1898 Fluid - Differential: Removal and Replacement Front Drive Axle Front Axle Lubricant Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Clean the area around the front axle fill plug and the drain plug. 4. Remove the fill plug. 5. Remove the drain plug. 6. Drain the fluid from the front differential carrier assembly. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the drain plug. Tighten the drain plug to 33 Nm (24 lb ft). 2. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Approximate Fluid Capacities (See: Specifications) and Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). 3. Install the fill plug. Tighten the fill plug to 33 Nm (24 lb ft). 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 5. Lower the vehicle. Differential Oil Replacement (8.6 Inch Axle) Differential Oil Replacement (8.6 Inch Axle) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 1899 Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Clean the area around the rear axle fill plug. 3. Remove the rear axle fill plug. 4. Remove the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 5. Drain the lubricant into a suitable container. Installation Procedure 1. Install the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 2. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities (See: Specifications) and Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 4. Lower the vehicle. Differential Oil Replacement (9.5LD Inch Axle) Differential Oil Replacement (9.5LD Inch Axle) Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 1900 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the drain plug. 3. Remove the fill plug. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the drain plug and tighten to 33 Nm (24 lb ft). 2. Fill the rear drive axle. * Use the proper fluid, refer to Approximate Fluid Capacities (See: Specifications). * For the proper capacity, refer to Fluid and Lubricant Recommendations (USA and Canada) (See: ). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 1901 3. Install the fill plug and tighten to 33 Nm (24 lb ft). 4. Remove the support and lower the vehicle. Differential Oil Replacement (10.5 Inch Axle) Differential Oil Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the fill plug (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 1902 3. Remove the rear axle drain plug (1). 4. Drain the lubricant into a suitable container. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the rear axle drain plug (1) and tighten to 33 Nm (24 lb ft). 2. Fill the rear axle with the proper fluid. Refer to Approximate Fluid Capacities (See: Specifications) and Fluid and Lubricant Recommendations (USA and Canada) (See: ). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 1903 3. Install the fill plug (1) and tighten to 33 Nm (24 lb ft). 4. Remove the support and lower the vehicle. Differential Oil Replacement (11.5 Inch Axle) Differential Oil Replacement (11.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) in General Information. 2. Remove the fill plug. 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 1904 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the rear axle drain plug and tighten to 33 Nm (24 lb ft). 2. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities (See: Specifications) and Fluid and Lubricant Recommendations (USA and Canada) (See: ) in Maintenance and Lubrication. 3. Install the fill plug and washer and tighten to 33 Nm (24 lb ft). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications TRANSFER CASE FLUID BW 4485-NR3 ..................................................................................................................................... ...................................... Fill to bottom of drain hole. MP 1222/1225/1226-NQG ................................................................................................................... ............................................... 1.6 quarts (1.5 liters) MP 1625/1626-NQF ............................................................................................................................ ................................................ 1.6 quarts (1.5 liters) MP 3023/3024-NQH ............................................................................................................................ ............................................... 1.6 quarts (1.5 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1909 Fluid - Transfer Case: Fluid Type Specifications TRANSFER CASE FLUID DEXRON-VI Automatic Transmission Fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case Fluid - Transfer Case: Service and Repair BW 4485-NR3 - Transfer Case Transfer Case Fluid Replacement Removal Procedure Note: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Transmission and Drivetrain/Transfer Case/Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 3. Remove the fill plug. 4. Remove the drain plug. Note: Ensure that an approved drain pan is used when draining the transfer case. 5. Allow the transfer case to drain completely. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 1912 Note: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the drain and fill plugs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the drain plug. Tighten the plug to 25 Nm (18 lb ft). 3. Fill the transfer case to the bottom of the fill plug hole with the recommended fluid. 4. Install the fill plug. Tighten the plug to 25 Nm (18 lb ft). 5. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Transmission and Drivetrain/Transfer Case/Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 1913 Fluid - Transfer Case: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Transfer Case Fluid Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 1914 Fluid - Transfer Case: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Fluid Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 1915 Fluid - Transfer Case: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Fluid Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up Engine Oil: Customer Interest Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 1924 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: All Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1930 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1931 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up Engine Oil: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 1936 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: All Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1942 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1943 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ............................................... 6.0 quarts (5.7 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1946 Engine Oil: Fluid Type Specifications ENGINE OIL TYPE Look for three things: 1. Your vehicle's engine requires oil meeting GM Standard GM6094M. 2. Oils meeting these requirements should also have the starburst symbol on the container. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). You should look for this information on the oil container 3. All temperatures above -20°F (-29°C) SAE 5W-30 is best for your vehicle. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 10W-40, SAE 20W-50, or any other viscosity grade not recommended. NOTICE: Use only engine oil identified as meeting GM Standard GM6094M and showing the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by your warranty. GM Goodwrench oil meets all the requirements for your vehicle. If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will provide easier cold starting and better protection for your engine at extremely low temperatures. ENGINE OIL ADDITIVES / ENGINE OIL FLUSHES Do not add anything to your oil. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all you will need for good performance and engine protection. Engine oil system flushes are not recommended and could cause engine damage not covered by the vehicle warranty. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1947 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to drain completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and inspect the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1948 10. Position the drain pan under the oil filter (437). 11. Remove the oil filter. 12. Ensure that the oil filter gasket is still on the old filter if not, remove the oil filter gasket from the oil pan. Installation Procedure 1. Apply clean engine oil to the NEW oil filter seal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW oil filter (437) and tighten to 30 Nm (22 lb ft). 3. Tighten the oil pan drain plug (430) to 25 Nm (18 lb ft). 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities (See: Specifications) and Fluid and Lubricant Recommendations Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1949 (USA and Canada) (See: ). 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1957 Refrigerant: Fluid Type Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1958 Refrigerant: Service and Repair Refrigerant Recovery and Recharging (Non-HP2) Special Tools * J 43600 - ACR 2000 Air Conditioning Service Center * J 45037 - A/C Oil Injector For equivalent regional tools, refer to Special Tools (See: Heating and Air Conditioning/Tools and Equipment/Heating, Ventilation, and Air Conditioning). Warning To prevent personal injury, avoid breathing A/C Refrigerant and lubricant vapor or mist. Work in a well ventilated area. To remove refrigerant from the A/C System, use service equipment designed for recovery that is certified to meet the requirements of the appropriate SAE Standards. If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant, refrigerant recovery, and lubricant manufacturers. Warning For personal protection, goggles and lint-free gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Caution: You must replace the desiccant if the A/C refrigerant system has been open to atmosphere for more than four hours, or if the A/C refrigerant oil has been contaminated. Failure to replace the desiccant will result in damage to the A/C refrigerant system. Caution: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. Caution: To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Caution: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. Caution: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 - service center is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 - service center ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Specifications (Non-HP2) (See: Refrigerant Oil/Specifications) for the correct amount. A/C Refrigerant System Oil Charge Replenishing If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 - injector. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Specifications (Non-HP2) (See: Refrigerant Oil/Specifications). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1963 Refrigerant Oil: Fluid Type Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake Automated Bleed Procedure Less Than 3900 KG (8600 Lb) GVW Antilock Brake System Automated Bleed Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings). Note: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Using the scan tool, begin the automated bleed procedure. 4. Follow the instructions on the scan tool to complete the automated bleed procedure. Apply the brake pedal when instructed by the scan tool. 5. Turn the ignition OFF. 6. Remove the scan tool from the vehicle. 7. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). 9. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 10. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 11. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 12. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 13. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). 14. Drive the vehicle to exceed 13 km/h (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 15. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Greater Than/Equal to 3900 KG (8600 Lb) GVW Antilock Brake System Automated Bleed Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings). Note: * Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). * The automated bleed procedure must be performed when a new brake pressure modulator valve (BPMV) is installed, because the secondary circuits of the new BPMV are not prefilled with brake fluid. * The automated bleed procedure is recommended when one of the following conditions exist: * Base brake system bleeding does not achieve the desired pedal height or feel * Extreme loss of brake fluid has occurred * Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out away from the brake modulator assembly, which is then forced out at the brake corners by the pressure bleeder. Automated Bleed Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 1968 Caution: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Repair or replace components as needed. 4. Lower the vehicle. 5. Prepare the brake bleeding equipment and the vehicle for a pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). 6. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics). 7. Install a scan tool. 8. Turn the ignition ON, with the engine OFF. 9. With the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Special Functions 6. Select Automated Bleed 10. With an assistant ready, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). Note: * Apply the brake pedal when instructed, using moderate effort. * Ensure the pedal remains applied until instructed to release by the scan tool. * Do not exceed the time period allowed by the scan tool for having the bleeder valves open. * The bleed sequence for each corner is as follows: - Left front - Right front - Right rear - Left rear 11. Perform the automated bleed procedure as instructed by the scan tool. 12. If the automated bleed procedure is aborted, a malfunction exists. If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) to diagnose the DTC. 13. After completion of the automated bleed procedure, press and hold the brake pedal to inspect for pedal firmness. 14. If the brake pedal feels spongy, repeat the bleed procedure completely. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 17. Lower the vehicle. 18. Adjust the brake fluid level. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). 19. Road test the vehicle while confirming the brake pedal remains high and firm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 1969 Brake Bleeding: Service and Repair Hydraulic Brake Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: ). If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: ). 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 1970 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 1971 Brake Bleeding: Service and Repair Hydraulic Brake Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) Special Tools * J-29532 - Diaphragm Pressure Bleeder, or equivalent * J-35589-A - Brake Pressure Bleeder Adapter Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 6. Check the brake fluid level in the J-29532 - Diaphragm Pressure Bleeder, or equivalent. Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , to the J-35589-A - Brake Pressure Bleeder Adapter. 8. Charge the J-29532 - Diaphragm Pressure Bleeder, or equivalent , air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 1972 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve, then disconnect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , from the J-35589-A - Brake Pressure Bleeder Adapter. 23. Remove the J-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to the following procedures, as appropriate: * Antilock Brake System Automated Bleed (See: )for Two-mode Hybrid vehicles * Antilock Brake System Automated Bleed (See: )for non-hybrid vehicles less than 3900 kg (8600 lb) GVW * Antilock Brake System Automated Bleed (See: )for non-hybrid vehicles greater than/equal to 3900 kg (8600 lb) GVW 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 1973 Brake Bleeding: Service and Repair Hydraulic Brake Flushing Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance - oil-based substance - Layered appearance - silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (Vacuum Assist) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement )Master Cylinder Replacement (Hydraulic Assist) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) * Front Brake Hose Replacement (JH6, JH7) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JH6, JH7))Front Brake Hose Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JD9, JF3, JF7, JG4)) * Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4))Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4))Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JH6, JH7))Rear Brake Hose Replacement (To Caliper - JD9) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Caliper - JD9))Rear Brake Hose Replacement (Caliper - JH6, JH7) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper - JH6, JH7)) * Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) * Rear Brake Caliper Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Less than 3900 kg (8600 lb) GVW) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 1974 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (Vacuum Assist) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement )Master Cylinder Replacement (Hydraulic Assist) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) ; also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (Vacuum Assist) (See: Brakes and Traction Control/Hydraulic System/Brake Fluid Reservoir/Service and Repair/Master Cylinder Reservoir Replacement (Vacuum Assist))Master Cylinder Reservoir Replacement (Hydraulic Assist) (See: Brakes and Traction Control/Hydraulic System/Brake Fluid Reservoir/Service and Repair/Master Cylinder Reservoir Replacement (Hydraulic Assist))Master Cylinder Reservoir Replacement (Two-mode Hybrid) (). Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (JH6, JH7) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JH6, JH7))Front Brake Hose Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JD9, JF3, JF7, JG4)) * Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4))Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4))Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JH6, JH7))Rear Brake Hose Replacement (To Caliper - JD9) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Caliper - JD9))Rear Brake Hose Replacement (Caliper - JH6, JH7) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper - JH6, JH7)) * Front Brake Caliper Overhaul (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Overhaul/Front Brake Caliper Overhaul (JH6, JH7)) or Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) * Rear Brake Caliper Overhaul (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Overhaul/Rear Brake Caliper Overhaul (JH6, JH7)) or Rear Brake Caliper Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Less than 3900 kg (8600 lb) GVW) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canada P/N 992667) or equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 1978 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual Fuse: Locations Center Instrument Panel Fuse Block - Owners Manual CENTER INSTRUMENT PANEL FUSE BLOCK The center instrument panel fuse block is located underneath the instrument panel, to the left of the steering column. TOP VIEW HARNESS CONNECTOR - USAGE BODY 2 ............................................................................................................................................... ................................... Body Harness Connector 2 BODY 1 ............................................................... ................................................................................................................... Body Harness Connector 1 BODY 3 ............................................................................................................................................ ...................................... Body Harness Connector 3 HEADLINER 3 .................................................. .............................................................................................................. Headliner Harness Connector 3 HEADLINER 2 ................................................................................................................ ................................................ Headliner Harness Connector 2 HEADLINER 1 ................................. ............................................................................................................................... Headliner Harness Connector 1 SEO/UPFITTER .......................................................................................................................... Special Equipment Option Upfitter Harness Connector CIRCUIT BREAKER - USAGE CB1 ......................................................................................................................................................... Passenger Side Power Window Circuit Breaker CB2 ......................................................................... .......................................................................................................... Passenger Seat Circuit Breaker CB3 ...................................................................................................................................................... .................................. Driver Seat Circuit Breaker CB4 ....................................................................... .......................................................................................................................... Rear Sliding Window Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 1984 Fuse: Locations Instrument Panel Fuse Block - Owners Manual INSTRUMENT PANEL FUSE BLOCK The instrument panel fuse block access door is located on the driver side edge of the instrument panel. Pull off the cover to access the fuse block. The vehicle may not use all of the fuses shown. FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. .............................................................. Rear Seats Fuse 2 ................................................................ .................................................................................................................. Rear Accessory Power Outlet Fuse 3 ....................................................................................................................................... ................................... Steering Wheel Controls Backlight Fuse 4 ...................................................... .......................................................................................................................................... Driver Door Module Fuse 5 ..................................................................................................................................... ............................... Dome Lamps, Driver Side Turn Signal Fuse 6 .................................................... ...................................................................................................................... Driver Side Turn Signal, Stoplamp Fuse 7 ................................................................................................................................. .............................................. Instrument Panel Back Lighting Fuse 8 ................................................ .................................................................................................................... Passenger Side Turn Signal, Stoplamp Fuse 9 ..................................................................................................................... ............................................. Passenger Door Module, Driver Unlock Fuse 10 .................................. ................................................................................................................................. Power Door Lock 2 (Unlock Feature) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 1985 Fuse 11 ................................................................................................................................................ ....................... Power Door Lock 2 (Lock Feature) Fuse 12 ......................................................................................................................................................... Stoplamps, Center-High Mounted Stoplamp Fuse 13 ......................................................................... .................................................................................................................. Rear Climate Controls Fuse 14 ................................................................................................................................................ ......................................................... Power Mirror Fuse 15 ................................................................ ............................................................................................................... Body Control Module (BCM) Fuse 16 ................................................................................................................................................ ....................................... Accessory Power Outlets Fuse 17 .............................................................. ......................................................................................................................................... Interior Lamps Fuse 18 .................................................................................................................................... ............................... Power Door Lock 1 (Unlock Feature) Fuse 19 .................................................... .................................................................................................................................... Rear Seat Entertainment Fuse 20 ..................................................................................................................................................... Ultrasonic Rear Parking Assist, Power Liftgate Fuse 21 ..................................................................... .................................................................................................. Power Door Lock 1 (Lock Feature) Fuse 22 ................................................................................................................................................ ........................... Driver Information Center (DIC) Fuse 23 ................................................................. ............................................................................................................................................ Rear Wiper Fuse 24 ..................................................................................................................................... ..................................................................... Cooled Seats Fuse 25 .............................................................................................................................................. Driver Seat Module, Remote Keyless Entry System Fuse 26 ........................................................................................................................................................... Driver Power Door Lock (Unlock Feature) CIRCUIT BREAKER ............................................................................................................................ ................................................................ USAGE LT DR .......................................................................................................................................................... Driver Side Power Window Circuit Breaker HARNESS CONNECTOR ................................................................................................................... ................................................................. USAGE LT DR .................................................................................................................................................. .......................... Driver Door Harness Connection BODY .................................................................. ................................................................................................................................ Harness Connector BODY ................................................................................................................................. ................................................................. Harness Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 1986 Fuse: Locations Underhood Fuse Block - Owners Manual UNDERHOOD FUSE BLOCK The underhood fuse block is located in the engine compartment, on the driver side of the vehicle. Lift the cover to access the fuse block. Notice: Spilling liquid on any electrical components on the vehicle may damage it. Always keep the covers on any electrical component. To remove fuses, hold the end of the fuse between your thumb and index finger and pull straight out. FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. ............................... Right Trailer Stop/Turn Lamp Fuse 2 ......................................................................................................................... Electronic Suspension Control, Automatic Level Control Exhaust Fuse 3 ............................................................................... .................................................................................................... Left Trailer Stop/Turn Lamp Fuse 4 .............................................................................................................................................................. ......................................... Engine Controls Fuse 5 ............................................................................. .................................................................................. Engine Control Module, Throttle Control Fuse 6 ........................................................................................................................................................... ............................... Trailer Brake Controller Fuse 7 ........................................................................... ................................................................................................................................ Front Washer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 1987 Fuse 8 .................................................................................................................................................. ....................................................... Oxygen Sensor Fuse 9 ................................................................ ........................................................................................................................ Antilock Brakes System 2 Fuse 10 ................................................................................................................................ .......................................................... Trailer Back-up Lamps Fuse 11 ............................................... .......................................................................................................................... Driver Side Low-Beam Headlamp Fuse 12 ............................................................................................................ .............................................................. Engine Control Module (Battery) Fuse 13 ............................................................................................................................................................. Fuel Injectors, Ignition Coils (Right Side) Fuse 14 .............................................................................. .................................................................................. Transmission Control Module (Battery) Fuse 15 ......................................................................................................................................................... ................................ Vehicle Back-up Lamps Fuse 16 ........................................................................ ........................................................................................... Passenger Side Low-Beam Headlamp Fuse 17 ................................................................................................................................................ ................................ Air Conditioning Compressor Fuse 18 ................................................................ ..................................................................................................................................... Oxygen Sensors Fuse 19 ................................................................................................................................. .......................................... Transmission Controls (Ignition) Fuse 20 ................................................. ............................................................................................................................................................. Fuel Pump Fuse 21 ............................................................................................................................. .................................................... Fuel System Control Module Fuse 22 ............................................ .............................................................................................................................................................. ...... Not Used Fuse 23 ......................................................................................................................... ....................................................................................... Not Used Fuse 24 ........................................ ....................................................................................................................... Fuel Injectors, Ignition Coils (Left Side) Fuse 25 ..................................................................................................................... ........................................................................... Trailer Park Lamps Fuse 26 .................................... ..................................................................................................................................................... Driver Side Park Lamps Fuse 27 ......................................................................................................... .......................................................................... Passenger Side Park Lamps Fuse 28 ...................... .............................................................................................................................................................. ......................... Fog Lamps Fuse 29 ................................................................................................... .................................................................................................................... Horn Fuse 30 .................. ................................................................................................................................................. Passenger Side High-Beam Headlamp Fuse 31 ................................................................................. ........................................................................................... Daytime Running Lamps (DRL) Fuse 32 . .............................................................................................................................................................. ......... Driver Side High-Beam Headlamp Fuse 33 .............................................................................. ....................................................................................................... Daytime Running Lights 2 Fuse 34 ......................................................................................................................................................... ......................................................... Sunroof Fuse 35 ....................................................................................................................................................... Key Ignition System, Theft Deterrent System Fuse 36 ........................................................................ .......................................................................................................................... Windshield Wiper Fuse 37 ................................................................................................................................................ .......................... SEO B2 Upfitter Usage (Battery) Fuse 38 ................................................................ ..................................................................................................................... Electric Adjustable Pedals Fuse 39 .................................................................................................................................... ................................................. Climate Controls (Battery) Fuse 40 ................................................... .................................................................................................................................... Airbag System (Ignition) Fuse 41 ................................................................................................................................. .............................................................................. Amplifier Fuse 42 .................................................. ....................................................................................................................................................... Audio System Fuse 43 ........................................................................................................................ ....................................... Miscellaneous (Ignition), Cruise Control Fuse 44 ........................................ .............................................................................................................................................................. .......... Not Used Fuse 45 ..................................................................................................................... ................................................................... Airbag System (Battery) Fuse 46 .................................... .................................................................................................................................................... Instrument Panel Cluster Fuse 47 ....................................................................................................... .............................................................................................. Power Take-Off Fuse 48 ...................... ............................................................................................................................................... Auxiliary Climate Control (Ignition) Fuse 49 ........................................................................................................................................................... Center High-Mounted Stoplamp (CHMSL) Fuse 50 ............................................................................ ............................................................................................................................ Rear Defogger Fuse 51 ......................................................................................................................................................... .............................................. Heated Mirrors Fuse 52 ........................................................................ .................................................................................................. SEO B1 Upfitter Usage (Battery) Fuse 53 ............................................................................................................................................................. Cigarette Lighter, Auxiliary Power Outlet Fuse 54 ............................................................................... ................................................................................................................ SEO Upfitter Usage Fuse 55 ......................................................................................................................................................... ........................... Climate Controls (Ignition) Fuse 56 .................................................................................................................................... Engine Control Module, Secondary Fuel Pump (Ignition) J-CASE FUSES ................................................................................................................................... ................................................................... USAGE Fuse 57 ................................................................................................................................................ ........................................................ Cooling Fan 1 Fuse 58 ............................................................... ................................................................................................................................................. Not Used Fuse 59 ...................................................................................................................................... ................................ Heavy Duty Antilock Brake System Fuse 60 ...................................................... .................................................................................................................................................. Cooling Fan 2 Fuse 61 ........................................................................................................................ ............................................................... Antilock Brake System 1 Fuse 62 ........................................ .............................................................................................................................................................. .............. Starter Fuse 63 ..................................................................................................................... ..................................................................... Stud 2 (Trailer Brakes) Fuse 64 .................................... ......................................................................................................................................... Left Bussed Electrical Center 1 Fuse 65 ................................................................................................................. ............................................................................................... Not Used Fuse 66 ................................ ....................................................................................................................................... Heated Windshield Washer System Fuse 67 ................................................................................................... ...................................................................................................... Transfer Case Fuse 68 ........................................................................................................ Stud 1 (Trailer Connector Battery Power) (Optional - 40A Fuse Required) Fuse 69 .................................................. ........................................................................................................................... Mid-Bussed Electrical Center 1 Fuse 70 ................................................................................................................. ........................................................................ Climate Control Blower Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 1988 Fuse 71 ................................................................................................................................................ ................................................................ Not Used Fuse 72 ............................................................... .............................................................................................................. Left Bussed Electrical Center 2 RELAYS .............................................................................................................................................. .................................................................... USAGE FAN HI ................................................................................................................................................. ...................................... Cooling Fan High Speed FAN LO ................................................................ ....................................................................................................................... Cooling Fan Low Speed FAN CNTRL ............................................................................................................................. ........................................................ Cooling Fan Control HDLP LO/HID ............................................ .................................................................................................................................... Low-Beam Headlamp FOG LAMP ......................................................................................................................... ................................................................... Front Fog Lamps A/C CMPRSR ...................................... ............................................................................................................................... Air Conditioning Compressor STRTR ............................................................................................................................ ........................................................................................ Starter PWR/TRN ....................................... .............................................................................................................................................................. ... Powertrain FUEL PMP .................................................................................................................... ................................................................................... Fuel Pump PRK LAMP .................................... ............................................................................................................................................................ Parking Lamps REAR DEFOG ............................................................................................................ ............................................................................... Rear Defogger RUN/CRANK ............................... .......................................................................................................................................................... Switched Power Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Fuse: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1991 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1992 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1993 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1994 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1995 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1996 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1997 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1998 Fuse Block - Underhood Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1999 Fuse Block - Underhood X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2000 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2001 Fuse Block - Underhood X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2002 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2003 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2004 Fuse Block - Underhood X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2005 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2006 Fuse Block - Underhood X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2007 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2008 Fuse Block - Underhood X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2009 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2010 Fuse Block - Underhood X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2011 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2012 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2013 Fuse: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2014 Fuse Block - I/P Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2015 Fuse Block - I/P Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2016 Fuse Block - I/P X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2017 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2018 Fuse Block - I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2019 Fuse Block - I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2020 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2021 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2022 Fuse: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2023 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2024 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2025 Fuse: Application and ID Fuse Holder Electrical Center Identification Views Fuse Block - Auxiliary, Fuse Holder (HP2) Fuse Block - Auxiliary, Fuse Holder (HP2) Fuse Holder X1 (Gas except 9L4) Fuse Holder X1 (Diesel or Gas with 9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2026 Fuse Holder X2 (Gas with TP2) Fuse Holder X2 (Diesel or Gas except LU3) Fuse Holder X2 (LU3) Fuse Holder X2 (Gas except LU3) Fuse Holder X2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2027 Fuse Holder X3 (9L4) Fuse Holder X3 (Diesel) Fuse Holder X4 (TP2) Fuse Holder X4 (Diesel) Fuse Holder X4 (Diesel with K76 or YF2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2028 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2029 Fuse: Application and ID Junction Block Electrical Center Identification Views Junction Block - Left I/P, Label Junction Block - Left I/P, Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2030 Junction Block - Left I/P, Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2031 Junction Block - Left I/P X1 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2032 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2033 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2034 Junction Block - Left I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2035 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2036 Junction Block - Left I/P X3 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2037 Junction Block - Left I/P X4 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2038 Junction Block - Left I/P X5 (SPO Alarm or SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2039 Junction Block - Left I/P X7 (JF4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2040 Junction Block - Left I/P X8 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2041 Junction Block - Left I/P X9 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2042 Junction Block - Left I/P X10 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2043 Junction Block - Left I/P X11 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2044 Junction Block - Left I/P X12 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2045 Junction Block - Left I/P X13 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2046 Junction Block - Left I/P X14 (5X7, 5Y0, 9L4, SPO DVD or SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2047 Junction Block - Right I/P, Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2048 Junction Block - Right I/P (Wire Entry) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2049 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2050 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2051 Junction Block - Right I/P X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2052 Junction Block - Right I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2053 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2054 Junction Block - Right I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2055 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2056 Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2057 Junction Block - Rear Lamps X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2058 Junction Block - Rear Lamps X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2059 Junction Block - Rear Lamps X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2064 Fuse Block - I/P Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2065 Fuse Block - I/P Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2066 Fuse Block - I/P X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2067 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2068 Fuse Block - I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2069 Fuse Block - I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2070 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2071 Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2072 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2073 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2074 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2075 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2076 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2077 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2078 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2079 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2080 Fuse Block - Underhood Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2081 Fuse Block - Underhood X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2082 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2083 Fuse Block - Underhood X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2084 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2085 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2086 Fuse Block - Underhood X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2087 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2088 Fuse Block - Underhood X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2089 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2090 Fuse Block - Underhood X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2091 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2092 Fuse Block - Underhood X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2093 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2094 Fuse Block - Underhood X8 (JL1) Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2095 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2096 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2097 Fuse Block: Connector Locations Harness Routing Views Chassis Harness Routing (Except LY6/LMM/HP2) 1 - X300 2 - X408 (UD7) 3 - G401 4 - J423 (except LU3) 5 - J331 6 - Fuse Block - Underhood X3 7 - X115 8 - X102 (JL1) 9 - J338 (except LU3/LMG) 10 - J300 11 - G300 Chassis Harness Routing (LY6/LMM except 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2098 1 - X300 2 - X408 (UD7) 3 - Trailer Connector (UY7) 4 - J411 (JL1) 5 - G401 6 - J331 7 - Fuse Block - Underhood X3 8 - X115 9 - X102 (JL1) 10 - J300 11 - G300 Chassis Harness - Front Engine Compartment (31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2099 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Driver Door Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2100 1 - Door Frame 2 - Fuse Block - I/P X4 3 - J502 (YE9 without AN3) 4 - X500 (YE9 without AN3/DL3) 5 - X502 (ASF without YE9 or with AN3) Engine Harness Routing - Left Side (4.3L) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2101 1 - Throttle Body 2 - G107 3 - Transmission 4 - X300 5 - X109 6 - X110 (NQG/NQH) 7 - Fuse Block - Underhood X2 Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2102 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2103 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) I/P Harness Routing - Engine Compartment (Except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2104 1 - G110 (XA7) 2 - J113 (NQH) 3 - Fuse Block - Underhood X5 4 - Fuse Block - Underhood X4 5 Left Front Fender 6 - X103 7 - X109 8 - X115 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2107 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2108 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2109 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2110 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2111 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2112 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2113 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2114 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2115 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2116 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2117 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2118 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2119 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2120 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2121 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2122 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2123 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2124 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2125 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2126 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2127 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2128 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2129 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2130 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2131 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2132 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2133 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2134 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2135 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2136 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2137 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2138 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2139 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2140 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2141 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2142 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2143 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2144 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2145 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2146 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2147 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2148 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2149 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2150 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2151 Fuse Block: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2152 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2153 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2154 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2155 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2156 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2157 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2158 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2159 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2160 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2161 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2162 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2163 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2164 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2165 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2166 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2167 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2168 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2169 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2170 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2171 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2172 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2173 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2174 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2175 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2176 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2177 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2178 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2179 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2180 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2181 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2182 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2183 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2184 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2185 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2186 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2187 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2188 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2189 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2190 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2192 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2193 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2194 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2195 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2196 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2197 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2198 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2199 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2200 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2201 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2202 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2203 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2204 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2205 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2206 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2207 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2208 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2209 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2210 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2211 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2215 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2216 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2217 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2218 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2219 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2220 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2221 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2222 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2223 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2224 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2225 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2226 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2227 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2228 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2229 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2230 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2231 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2232 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2233 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2234 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2235 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2236 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2237 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2238 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2239 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2240 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2241 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2242 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2243 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2244 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2245 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2246 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2247 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2248 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2249 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2250 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2251 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2252 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2253 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2254 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2255 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2256 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2257 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2258 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2259 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2260 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2261 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2262 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2263 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2264 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2265 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2266 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2267 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2268 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2269 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2270 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2271 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2272 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2273 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2274 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2275 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2276 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2277 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2278 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2279 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2280 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2281 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2282 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2283 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2284 Fuse Block: Connector Views Electrical Center Identification Views Junction Block - Left I/P, Label Junction Block - Left I/P, Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2285 Junction Block - Left I/P, Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2286 Junction Block - Left I/P X1 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2287 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2288 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2289 Junction Block - Left I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2290 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2291 Junction Block - Left I/P X3 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2292 Junction Block - Left I/P X4 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2293 Junction Block - Left I/P X5 (SPO Alarm or SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2294 Junction Block - Left I/P X7 (JF4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2295 Junction Block - Left I/P X8 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2296 Junction Block - Left I/P X9 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2297 Junction Block - Left I/P X10 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2298 Junction Block - Left I/P X11 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2299 Junction Block - Left I/P X12 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2300 Junction Block - Left I/P X13 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2301 Junction Block - Left I/P X14 (5X7, 5Y0, 9L4, SPO DVD or SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2302 Junction Block - Right I/P, Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2303 Junction Block - Right I/P (Wire Entry) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2304 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2305 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2306 Junction Block - Right I/P X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2307 Junction Block - Right I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2308 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2309 Junction Block - Right I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2310 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2311 Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2312 Junction Block - Rear Lamps X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2313 Junction Block - Rear Lamps X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2314 Junction Block - Rear Lamps X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures Fuse Block: Procedures Ground Repair Electrical Grounds Proper electrical system function relies on secure, positive, corrosion-free ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacements. In general, electrical ground connections are accomplished using one, or a combination of, three attachment methods: * Welded M6 stud and nut * Welded M6 nut and bolt * Welded M8 nut and bolt Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. Determine which attachment method is used, and carry out the appropriate repair. M6 Weld Stud Replacement 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 5. Select a replacement conductive M6 rivet stud. Refer to GM parts catalog for the correct part number and application. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new rivet stud. 16. Select a new, conductive M6 nut. Refer to GM parts catalog for the correct part number and application. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 17. Install the M6 nut and tighten to 8 Nm (71 lb in). 18. Check for proper system operation. M6 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a new, conductive self-threading M7 bolt may be used to secure the ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive, self-threading M7 bolt Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2317 threads. 5. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 6. Install the electrical ground terminal to the new, conductive M7 bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the M7 bolt and tighten to 9 Nm (80 lb in). 8. Check for proper system operation. M6 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a conductive M6 bolt and a conductive M6 nut may be used to secure the electrical ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 ) clearance behind the panel surface and 20 mm (0.79 ) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M6 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M6 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). Note: The repair area must be properly refinished to maintain positive electrical grounding. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a conductive M8 bolt and a conductive M8 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent to M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M8 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M8 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M8 nut and tighten to 22 Nm (16 lb ft). Note: The repair area must be properly refinished to maintain positive electrical grounding. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2318 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a conductive M6 rivet stud and a conductive M6 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new, conductive M6 rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new, conductive M6 rivet stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 16. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). 17. Check for proper system operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2319 Fuse Block: Removal and Replacement 175 Amp Mega Fuse Replacement (Diesel) 175 Amp Mega Fuse Replacement (Diesel) Removal Procedure 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the mega fuse cover (3). 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2320 5. Remove the auxiliary battery positive cable nut (1) from the mega fuse holder. 6. Remove the generator battery jumper cable to fuse nut (3). 7. Remove the generator battery jumper cable terminal (2) from the fuse stud. 8. Remove the auxiliary battery positive cable from the fuse studs. 9. Remove the upper mega fuse nut (1), if necessary. 10. Remove the appropriate mega fuse (2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2321 1. Install the appropriate mega fuse (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the upper mega fuse nut (1), if necessary. Tighten the nut to 15 Nm (11 lb ft). 3. Install the auxiliary battery positive cable to the fuse studs. 4. Install the generator battery jumper cable terminal (2) to the fuse stud. 5. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 9 Nm (80 lb in). 6. Install the auxiliary battery positive cable nut (1) to the mega fuse holder. Tighten the nut to 15 Nm (11 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2322 7. Install the starter solenoid cable terminal (2) to the fuse stud. 8. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 9. Install the mega fuse cover (3). 10. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 175 Amp Mega Fuse Replacement (Single Battery) 175 Amp Mega Fuse Replacement (Single Battery) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2323 175 Amp Mega Fuse Replacement (Auxiliary Battery) 175 Amp Mega Fuse Replacement (Auxiliary Battery) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2324 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2325 Instrument Panel Electrical Center or Junction Block Replacement - Left Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2326 Instrument Panel Electrical Center or Junction Block Replacement - Left Side Body Wiring Harness Junction Block Replacement Body Wiring Harness Junction Block Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2327 Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2328 Underhood Electrical Center or Junction Block Bracket Replacement Underhood Electrical Center or Junction Block Bracket Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2329 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2334 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2335 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2336 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2337 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2338 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2339 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2340 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2341 Fuse Block - Underhood Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2342 Fuse Block - Underhood X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2343 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2344 Fuse Block - Underhood X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2345 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2346 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2347 Fuse Block - Underhood X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2348 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2349 Fuse Block - Underhood X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2350 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2351 Fuse Block - Underhood X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2352 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2353 Fuse Block - Underhood X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2354 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2355 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2356 Relay Box: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2357 Fuse Block - I/P Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2358 Fuse Block - I/P Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2359 Fuse Block - I/P X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2360 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2361 Fuse Block - I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2362 Fuse Block - I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2363 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2364 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2365 Relay Box: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2366 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2367 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2373 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2374 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2375 Customer TPMS Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2376 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2377 Frequently Asked Questions Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR If your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator. This indicator is not a maintenance indicator and does not mean a maintenance service is required. For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information refer to Malfunction Indicator Lamp. For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. Reference Information Schematic Reference * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges and Warning Indicators/System Diagram/Instrument Cluster Schematics) * Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 2. Ignition ON, verify that a test lamp illuminates between the ignition circuit and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC. 3. Connect a test lamp between the control circuit and the ignition circuit. 4. Command the MIL ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, replace the IPC. Repair Instructions Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Page 2384 Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Instrument Cluster Replacement (Without RPO SLT) (See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (Without RPO SLT))Instrument Cluster Replacement (With RPO SLT) (See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (With RPO SLT)) * Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM replacement, setup, and programming Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair GM Oil Life System Resetting When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A CHANGE ENGINE OIL SOON message will come on. Change the engine oil as soon as possible within the next 1 000 km (600 miles). It is possible that, if driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. If the system is ever reset accidentally, change the engine oil at 5 000 km (3,000 miles) since last oil change. How to Reset the Engine Oil Life System The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Anytime the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where the oil is changed prior to a CHANGE ENGINE OIL SOON message being turned on, reset the system. If the vehicle does not have a Driver Information Center (DIC), do the following: 1. Turn the ignition to ON, with the engine OFF. 2. Fully press and release the accelerator pedal slowly three times within five seconds. 3. Turn the key to OFF. If the CHANGE ENGINE OIL SOON message comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the procedure. If the vehicle has a DIC, do the following: 1. Turn the ignition to ON, with the engine OFF. 2. Press the MODE button until the DIC reads OIL LIFE LEFT/HOLD SET TO RESET. 3. Press and hold the SET button until 100 percent is displayed. You will hear three chimes and the CHANGE ENGINE OIL SOON message will go off. 4. Turn the key to OFF. If the CHANGE ENGINE OIL SOON message comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle contents. For lifting the vehicle, various lift points are recommended. Before you begin any lifting procedure, place the vehicle on a clean, hard, level surface. Verify that all the lifting equipment meets weight standards and is in good working order. Verify that all of the vehicle loads are equally distributed and secure. If you are only supporting the vehicle at the frame side rails, verify that the lifting equipment does not put too much stress on, or weaken, the frame side rails. During hoisting, do NOT damage the fuel tanks, the exhaust system, or the underbody. 1 - Lower Control Arm Contact Points 2 - Front Frame Contact Points 3 - Rear Frame Contact Points 4 - Rear Axle Contact Points Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 2392 5 - Differential Contact Points Frame Contact Hoist Front Hoist Pads Note: The front hoist pads must not contact the rocker panels, the front fenders, or the floor pan. Position the front hoist pads under the front frame between the lower control arm and the frame pad. Rear Hoist Pads Note: The rear hoist pads must not contact the body rocker panels or the floor pan. Position the rear hoist pads under the rear spring, just behind the hanger Suspension Contact Hoist Front Lift Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 2393 Position the front lift under the outer edge of the front suspension lower control arms. Rear Lift Position the rear lift under the axle housing tubes on each side of the differential. Do not damage the stabilizer bar. Jacking When you are lifting a vehicle with a vehicle jack or a floor jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Under the Frame Rails Note: The floor jack pad must not contact rocker panel or the floor pan. Position the floor jack pad under the frame rail pad. Under the Rear Differential Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 2394 Position the floor jack pad under the center of the rear axle differential. Do not damage the establisher bar. Under the Rear Spring Hanger Position the jack under the rear spring hanger. Jack Stands When you support the vehicle with jack stands, place the jack stands under the frame, the front suspension crossmember, or the rear axle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-03-16-001 > Jul > 10 > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tire Pressure Module: > 11-01-38-001 > Feb > 11 > A/C - Excessive Cabin Moisture/Reduced Window Clearing Control Module HVAC: All Technical Service Bulletins A/C - Excessive Cabin Moisture/Reduced Window Clearing TECHNICAL Bulletin No.: 11-01-38-001 Date: February 28, 2011 Subject: Excessive Cabin Moisture / Reduced Window Clearing (Reprogram HVAC System Control Module) Models: 2010-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL All with RPO CJ3 or C67 (Manual Air Conditioning) Condition In rare cases, some customers may comment on excessive cabin moisture or difficulty keeping the windows clear in low ambient temperatures. Cause This concern may be caused by the recirculation door being in the recirculation position while the mode is set to a floor through defrost position. Correction Important DO NOT replace the HVAC control module for this concern. Revised software has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest software currently available in TIS2WEB. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tire Pressure Module: > 10-01-38-001 > Mar > 10 > A/C - Reduced Windshield Clearing/Defrost Control Module HVAC: All Technical Service Bulletins A/C - Reduced Windshield Clearing/Defrost TECHNICAL Bulletin No.: 10-01-38-001 Date: March 02, 2010 Subject: Reduced Windshield Clearing\Defrost at Low Ambient Temperatures (Reprogram HVAC Control Module) Models: 2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with HVAC System RPOs C42, C67 or CJ3 All Built Prior to February 17, 2010 Condition In rare cases, some customers may comment that the HVAC system has reduced defrost or added difficulty keeping the windshield clear in low ambient temperatures. Cause This condition may be caused by the airflow calibrations which can contribute to the above condition. Calibration changes at the start of the 2010 model year may not meet some customers' expectations. Testing has confirmed that defrost levels will meet requirements. Correction Important DO NOT replace the HVAC Control Module for this concern. Reprogram the HVAC Control Module with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest calibrations available on TIS2WEB. Refer to HVAC System Control Module Programming and Setup in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Monitor Receiver / Transponder: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Customer Interest for Tire Pressure Monitor Receiver / Transponder: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 2449 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 2450 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2453 Tighten the sensor nut to 7 Nm (62 lb in). Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2454 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2455 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in). Note: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Note: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2456 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2462 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2463 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2464 Customer TPMS Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2465 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2466 Frequently Asked Questions Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-03-10-008B > Jul > 10 > Wheels/Tires Module Programming For 20/22 Inch Wheels Tire Pressure Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Module: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Module: > 10-03-16-001 > Jul > 10 > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tire Pressure Module: > 10-03-16-001 > Jul > 10 > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Monitor Receiver / Transponder: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Customer Interest for Tire Pressure Monitor Receiver / Transponder: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 2506 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 2507 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2510 Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2511 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2512 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in). Note: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Note: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2513 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair Spare Tire: Service and Repair Spare Wheel Hoist Replacement Tire Hoist Secondary Latch Mechanism Note: If the spare tire hoist has been fully raised without a spare tire in place, the secondary latch mechanism may have become engaged. If this has occurred the hoist will not lower and the following steps will need to be followed: 1. Rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable (1) is exposed. 2. While holding the latch pin (3), fully depress the latch button (2) and release the secondary latch from the hoist assembly. Some side-to-side and/or up-and-down movement may be necessary to disengage the latch mechanism. 3. Continue rotating the hoist shaft counterclockwise in order to lower the hoist the rest of the way. 4. If this does not release the secondary latch, the spare tire hoist will need to be replaced. See the following procedure. Removal Procedure 1. If the vehicle is equipped with a spare tire stowage lock cylinder, open the spare tire lock cover on the bumper and using the ignition key, remove the lock. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 2518 Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 2. Rotate the hoist shaft counterclockwise in order to lower the spare tire to the ground. Continue to rotate the shaft until the spare tire can be pulled out from under the vehicle and removed. If the spare tire does not lower to the ground, the secondary latch is engaged causing the tire not to lower. 3. If the secondary latch is engaged and the cable end is visible, perform the following procedure: 1. Tighten the cable by rotating the hoist shaft clockwise until you hear 2 clicks or feel it skip twice. You cannot overtighten the cable. 2. Loosen the cable by rotating the hoist shaft counterclockwise 3 or 4 turns. 3. If the spare tire can be lowered, repeat steps 1 and 2 to see if the spare tire can be removed. 4. If the spare tire cannot be lowered, rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable is exposed. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 6. Place a transmission jack, or equivalent, under the spare tire. 7. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 8. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 9. Lower the tire. If the spare tire is hanging by the cable, rotate the hoist shaft counterclockwise until the tire is low enough to remove. 4. If the secondary latch is engaged and the cable end is NOT visible, perform the following procedure: 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Place a transmission jack, or equivalent, under the spare tire. 3. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 4. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 5. Lower the tire and remove it from the jack. 5. Raise and support the vehicle if it is not already raised. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 6. Depress the tabs, remove the guide shaft from the hoist collar, and slide the shaft toward the bumper. 7. Remove the collar from the hoist. 8. Remove the bolt. 9. Remove the hoist from the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 2519 10. Remove the spare tire hoist shaft guide from the bumper. Installation Procedure 1. Install the spare tire hoist shaft guide to the bumper. 2. Install the hoist to the crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolt and tighten to 40 Nm (30 lb ft). 4. Install the collar to the hoist. 5. Install the shaft to the hoist. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 2520 6. Install the spare tire to the hoist. Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 7. Rotate the hoist shaft clockwise until the spare tire is in position and the hoist clicks 2 times or it skips twice. You cannot overtighten the cable. 8. Remove the safety stands. 9. Lower the vehicle. 10. Install the spare tire stowage lock cylinder. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheels: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 2529 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2534 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2535 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2536 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 2541 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2546 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2547 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2548 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2554 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2555 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2556 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheels: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 2561 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 2566 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2571 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2572 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2577 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2578 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2579 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 2584 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2589 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2590 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2591 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation Heat Shield: All Technical Service Bulletins Exhaust - Muffler Heat Shield Buzz During Operation TECHNICAL Bulletin No.: 07-06-05-001I Date: March 22, 2011 Subject: V8 Engines - Muffler Heat Shield Buzz During Vehicle Operation (Perform Repair as Outlined) or Exhaust Pinging/Popping/Snapping Noise During Cool Down, at Idle, or After Vehicle is Shut Off (Normal Characteristic - No Repair Required) Models: 2007-2011 Cadillac Escalade, Escalade Hybrid, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Tahoe Hybrid 2007-2011 GMC Sierra, Sierra Denali, Yukon, Yukon Hybrid, Yukon XL, Yukon Denali, Yukon Denali XL Equipped with the following V8 Engines: - 4.8L (RPO LY2, L20) - 5.3L (RPOs LC9, LH6, LMG, LY5) - 6.0L (RPOs LFA, LY6, LZ1, L96) - 6.2L (RPOs L9H, L92, L94) Please Refer to GWM/IVH Supercede: This bulletin is being revised to update the Condition, Cause and Correction information. Please discard Corporate Bulletin Number 07-06-05-001H (Section 06 Engine/Propulsion System). Condition 1 Some customers may comment on a pinging/popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause 1 Exhaust Pinging/Popping/Snapping As the exhaust system cools, the muffler shell and muffler internals contract at different rates. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. Correction 1 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Exhaust Pinging/Popping/Snapping Noise (Normal) This condition is normal to the muffler design and does not indicate poor quality or part failure. No repairs are necessary for this condition. Replacing the muffler heat shield straps will NOT eliminate this noise. A new muffler may sound quiet for this condition, but as it ages may again produce this same condition. Condition 2 Some customers may also comment on a buzz noise coming from the muffler during vehicle operation. Cause 2 Muffler Heat Shield Buzz If the muffler heat shield straps are loose, the heat shield may be free to buzz during vehicle operation. Correction 2 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Muffler Heat Shield Buzz (Perform Repair) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation > Page 2597 Confirm the origin of the buzz by shimming (use metal shims) the straps tight and rerunning the vehicle. If the buzz concern is gone, then it is caused by the loose shield. Using the following procedure, install new straps to secure the heat shield to the muffler. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Mark the position of the heat shield (1) and straps (2) on the muffler shell. 3. Cut and remove the heat shield straps using tin snips along the muffler shell seam (1), and remove the shield from the muffler. 4. Position the heat shield to the muffler and install new heat shield straps on the muffler shell in the positions marked prior to removal. Important Do Not position the strap screw heads directly across from the propeller shaft. Ensure the strap heads are positioned below the midpoint of the muffler. 5. Position the strap screw heads (1) on the inboard side of the muffler. Ensure that the strap screw heads (1) are below the midpoint of the muffler. Tighten Tighten the straps to 4 Nm (35‹›lb‹›in). 6. Cut off the excess strap material and ensure that the ends (2) are flat against the muffler. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation > Page 2598 Warranty Information For vehicles with Exhaust Pinging/Popping/Snapping Noise, NO repairs are necessary as it is a normal condition. For vehicles repaired for a muffler buzz, use the labor operation. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation > Page 2604 Confirm the origin of the buzz by shimming (use metal shims) the straps tight and rerunning the vehicle. If the buzz concern is gone, then it is caused by the loose shield. Using the following procedure, install new straps to secure the heat shield to the muffler. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Mark the position of the heat shield (1) and straps (2) on the muffler shell. 3. Cut and remove the heat shield straps using tin snips along the muffler shell seam (1), and remove the shield from the muffler. 4. Position the heat shield to the muffler and install new heat shield straps on the muffler shell in the positions marked prior to removal. Important Do Not position the strap screw heads directly across from the propeller shaft. Ensure the strap heads are positioned below the midpoint of the muffler. 5. Position the strap screw heads (1) on the inboard side of the muffler. Ensure that the strap screw heads (1) are below the midpoint of the muffler. Tighten Tighten the straps to 4 Nm (35‹›lb‹›in). 6. Cut off the excess strap material and ensure that the ends (2) are flat against the muffler. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation > Page 2605 Warranty Information For vehicles with Exhaust Pinging/Popping/Snapping Noise, NO repairs are necessary as it is a normal condition. For vehicles repaired for a muffler buzz, use the labor operation. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Replacement Wheels Description Wheels: Description and Operation Replacement Wheels Description Replacement Wheels Description Replace the wheel if any of the following conditions exist: * The wheel exhibits excessive runout. * The wheel is bent. * The wheel is cracked. * The wheel is severely rusted. * The wheel is severely corroded. Note: Air leaks caused by porosity on aluminum wheels are repairable. * The wheel leaks air. Warning If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Caution: The use of non-GM original equipment wheels may cause: * Damage to the wheel bearing, the wheel fasteners and the wheel * Tire damage caused by the modified clearance to the adjacent vehicle components * Adverse vehicle steering stability caused by the modified scrub radius * Damage to the vehicle caused by the modified ground clearance * Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: * The wheel has elongated bolt holes. * The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Replacement Wheels Description > Page 2608 Wheels: Description and Operation Steel Wheel Repair Description Steel Wheel Repair Description Caution: Do not heat wheels in an attempt to soften them for straightening or repair damage from striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and uncontrolled heating from welding affects the properties of the material. Caution: The use of tubes in tubeless tires is not a recommended repair due to the fact that speed ratings are greatly reduced. You can repair porosity in aluminum wheels. If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 2609 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Guidelines Warning To avoid personal injury when exposed to plastic media blast, hand and/or lathe sanding dust, primer, color coat, and clearcoat, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs and protective gloves and clothing. Evaluating Damage Note: * Inspect the wheel for corrosion, scrapes, gouges, etc. Damage MUST NOT be deeper than what can be sanded or polished off. * Inspect the wheel for cracks. If cracks are found, discard the wheel. * ALL wheels with bent rim flanges must not be repaired or refinished. * The re-machining and the re-clear coating of aluminum wheels is not recommended in the dealer environment due to concerns of repair durability. * Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Aluminum Wheel Refinishing General Recommendations/Options * Painted aluminum wheels use a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. (See option number 1). * If the clearcoat is damaged, it is possible to refinish with clearcoat only, however, the required refinishing process cannot be performed in the dealer environment. Refer to Refinishers Responsibility (Repair option number 2). * Re-plating of chrome-plated aluminum wheels is not recommended. Repair Option Number 1 Material Required/Information Resources * The Paint Manufacturer's Color Book * Refer to the latest GM Approved Refinish Materials Booklet (GM 4901 MD-2005) for specific products for aluminum refinishing. * To access the booklet, go to www.gmgoodwrench.com. Click on GM Collision Parts. Click on GM Technical Repair Information, select Paint Shop. * A Color Compatibility chart is also at this site defining what colors are used on what models. Note: Chemical strippers are not recommended. * Refer to specific Paint Manufacturers for refinish procedures and process pertaining to "Aluminum Refinishing". The procedure requires the wheel surface to be plastic media blasted to remove old paint or clearcoat. General Color Selection * If the wheels being painted were previously clearcoated aluminum, and a painted aluminum look is desired, using Corsican Silver WAEQ9283 for a fine "aluminum-like" look, or Sparkle Silver WA9967 for a very bright look. Body color is another option to the customer that may also be used. * Some specific colors may be recommended on certain models. * If painting wheels that were previously clearcoated aluminum, it is recommended that all 4 wheels and their center caps be refinished to maintain color uniformity. General Refinishing Procedures - Removal 1. Remove the wheels from the vehicle. The tires may remain mounted on the wheels. 2. Remove the balance weights and mark their locations on the tire. 3. Remove excess grease, etc. from the wheels with wax and grease remover. 4. Have the wheels plastic media blasted to remove the clearcoat. Note: MASK OFF ALL MOUNTING SURFACES, whenever a wheel is refinished. The mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. 5. Clean and mask and paint the wheels. General Refinishing Procedures - Installation 1. Unmask the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 2610 2. Clean all wheel mounting surface of any corrosion, overspray, or dirt. Note: When re-balancing a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. 3. Install NEW coated balance weights at marked locations. Note: Use a torque stick on an impact wrench, or a torque wrench to consistently and uniformly fasten the wheel to the specified torque for the vehicle. The star pattern must be followed. 4. Install wheels on vehicle. Repair Option Number 2 - Outside Companies * Some outside companies are offering wheel refinishing services. One such company, Transwheel Corporation (800-892-3733), provides this service with GM guidelines. Other companies may also exist. * Any process that re-machines or otherwise remanufactures the wheel should not be used. * The wheel ID must be recorded and follow the wheel throughout the process to assure that the same wheel is returned. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is longer. * Paint and/or clearcoat must not be present on the following surfaces, the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. * A refinishers responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 2614 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Drive Shaft Nut ......................................................................................................................... .................................................... 240 Nm (177 lb ft) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 2627 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 2633 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Exhaust - Muffler Heat Shield Buzz During Operation TECHNICAL Bulletin No.: 07-06-05-001I Date: March 22, 2011 Subject: V8 Engines - Muffler Heat Shield Buzz During Vehicle Operation (Perform Repair as Outlined) or Exhaust Pinging/Popping/Snapping Noise During Cool Down, at Idle, or After Vehicle is Shut Off (Normal Characteristic - No Repair Required) Models: 2007-2011 Cadillac Escalade, Escalade Hybrid, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Tahoe Hybrid 2007-2011 GMC Sierra, Sierra Denali, Yukon, Yukon Hybrid, Yukon XL, Yukon Denali, Yukon Denali XL Equipped with the following V8 Engines: - 4.8L (RPO LY2, L20) - 5.3L (RPOs LC9, LH6, LMG, LY5) - 6.0L (RPOs LFA, LY6, LZ1, L96) - 6.2L (RPOs L9H, L92, L94) Please Refer to GWM/IVH Supercede: This bulletin is being revised to update the Condition, Cause and Correction information. Please discard Corporate Bulletin Number 07-06-05-001H (Section 06 Engine/Propulsion System). Condition 1 Some customers may comment on a pinging/popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause 1 Exhaust Pinging/Popping/Snapping As the exhaust system cools, the muffler shell and muffler internals contract at different rates. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. Correction 1 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Exhaust Pinging/Popping/Snapping Noise (Normal) This condition is normal to the muffler design and does not indicate poor quality or part failure. No repairs are necessary for this condition. Replacing the muffler heat shield straps will NOT eliminate this noise. A new muffler may sound quiet for this condition, but as it ages may again produce this same condition. Condition 2 Some customers may also comment on a buzz noise coming from the muffler during vehicle operation. Cause 2 Muffler Heat Shield Buzz If the muffler heat shield straps are loose, the heat shield may be free to buzz during vehicle operation. Correction 2 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Muffler Heat Shield Buzz (Perform Repair) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation > Page 2639 Confirm the origin of the buzz by shimming (use metal shims) the straps tight and rerunning the vehicle. If the buzz concern is gone, then it is caused by the loose shield. Using the following procedure, install new straps to secure the heat shield to the muffler. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Mark the position of the heat shield (1) and straps (2) on the muffler shell. 3. Cut and remove the heat shield straps using tin snips along the muffler shell seam (1), and remove the shield from the muffler. 4. Position the heat shield to the muffler and install new heat shield straps on the muffler shell in the positions marked prior to removal. Important Do Not position the strap screw heads directly across from the propeller shaft. Ensure the strap heads are positioned below the midpoint of the muffler. 5. Position the strap screw heads (1) on the inboard side of the muffler. Ensure that the strap screw heads (1) are below the midpoint of the muffler. Tighten Tighten the straps to 4 Nm (35‹›lb‹›in). 6. Cut off the excess strap material and ensure that the ends (2) are flat against the muffler. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation > Page 2640 Warranty Information For vehicles with Exhaust Pinging/Popping/Snapping Noise, NO repairs are necessary as it is a normal condition. For vehicles repaired for a muffler buzz, use the labor operation. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-06-05-003A > Feb > 11 > Exhaust System Exhaust Leak/Rattle/Rumble/Noises Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Exhaust System - Exhaust Leak/Rattle/Rumble/Noises TECHNICAL Bulletin No.: 10-06-05-003A Date: February 04, 2011 Subject: Exhaust Leak, Rattle, Rumble and/or Noise (Install New Clamp and Align Correctly) Models: 2009-2011 Cadillac Escalade Hybrid 2009-2011 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, Tahoe Hybrid 2009-2011 GMC Sierra 1500, Yukon, Yukon Hybrid, Yukon XL Equipped with 4.3L, 4.8L, 5.3L or 6.0L Engine 2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2011 Chevrolet Avalanche, Silverado, Suburban 2011 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL, Yukon Denali XL All Equipped with 6.2L Engine Supercede: This bulletin is being revised to add Parts Information. Please discard Corporate Bulletin Number 10-06-05-003 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an exhaust leak or noise. The noise may be described as a rattle or rumble. Cause This condition may be caused by an unseated pipe to pipe mid-joint connection as shown below. Correction Note Ensure that the pipe flares remain fully seated to each other while tightening the clamp. 1. Remove and discard the exhaust band (Norma) clamp. 2. Install and position a new exhaust band (Norma) clamp to the pipe joint. 3. Firmly push and maintain the pipes together while tightening the exhaust band (Norma) clamp bolt. Tighten Tighten the clamp bolt to 28 Nm (21 lb ft). Note After the clamp is installed, it does not need to be perpendicular to the pipe. It is acceptable to have a pipe to pipe or clamp angle. 4. Confirm that the clamp edges (both sides and all the way around the clamp) are fully seated on the pipe. 5. Run the engine and inspect the clamp joint to ensure there are no leaks and to ensure that the condition is corrected. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-06-05-003A > Feb > 11 > Exhaust System Exhaust Leak/Rattle/Rumble/Noises > Page 2645 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation > Page 2651 Confirm the origin of the buzz by shimming (use metal shims) the straps tight and rerunning the vehicle. If the buzz concern is gone, then it is caused by the loose shield. Using the following procedure, install new straps to secure the heat shield to the muffler. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Mark the position of the heat shield (1) and straps (2) on the muffler shell. 3. Cut and remove the heat shield straps using tin snips along the muffler shell seam (1), and remove the shield from the muffler. 4. Position the heat shield to the muffler and install new heat shield straps on the muffler shell in the positions marked prior to removal. Important Do Not position the strap screw heads directly across from the propeller shaft. Ensure the strap heads are positioned below the midpoint of the muffler. 5. Position the strap screw heads (1) on the inboard side of the muffler. Ensure that the strap screw heads (1) are below the midpoint of the muffler. Tighten Tighten the straps to 4 Nm (35‹›lb‹›in). 6. Cut off the excess strap material and ensure that the ends (2) are flat against the muffler. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation > Page 2652 Warranty Information For vehicles with Exhaust Pinging/Popping/Snapping Noise, NO repairs are necessary as it is a normal condition. For vehicles repaired for a muffler buzz, use the labor operation. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-06-05-003A > Feb > 11 > Exhaust System Exhaust Leak/Rattle/Rumble/Noises > Page 2657 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 2658 Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ..................................................... 190 Nm (140 lb ft) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 2659 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: * The wheel/nut has the word Metric stamped on the face. * The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. * M = Metric * 12 = Diameter in millimeters * 1.5 = Millimeters gap per thread Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the brake rotor. Refer to Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JD9, JF3, JF7, JG4))Front Brake Rotor Replacement (JH6, JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JH6, JH7)). 4. Use the J 43631 to press the stud from the wheel bearing/hub. Installation Procedure 1. Install a new stud. Use washers and a wheel nut and pull the new stud into the hub. 2. Install the brake rotor. Refer to Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JD9, JF3, JF7, JG4))Front Brake Rotor Replacement (JH6, JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JH6, JH7)). 3. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 2662 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement Special Tools J 43631 - Ball Joint Remover For equivalent regional tools, refer to Special Tools (See: Steering and Suspension/Suspension/Tools and Equipment/Rear Suspension) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 4. Remove the rear brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 5. Using the J 43631 - remover , remove wheel stud from the rear axle shaft. 6. For those vehicles equipped with RPO codes JH6 or JH7, remove the rear axle hub assembly. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 2663 1. Position the wheel stud in the rear axle shaft. 2. Using washers and a wheel nut, tighten the wheel nut until the wheel stud is firmly seated in the rear axle shaft. 3. Remove the wheel nut and the washers. 4. Install the rear axle hub assembly, if removed. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). 5. Install the brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 6. Install the rear brake drum. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 7. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 8. Remove the supports and lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle contents. For lifting the vehicle, various lift points are recommended. Before you begin any lifting procedure, place the vehicle on a clean, hard, level surface. Verify that all the lifting equipment meets weight standards and is in good working order. Verify that all of the vehicle loads are equally distributed and secure. If you are only supporting the vehicle at the frame side rails, verify that the lifting equipment does not put too much stress on, or weaken, the frame side rails. During hoisting, do NOT damage the fuel tanks, the exhaust system, or the underbody. 1 - Lower Control Arm Contact Points 2 - Front Frame Contact Points 3 - Rear Frame Contact Points 4 - Rear Axle Contact Points Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 2667 5 - Differential Contact Points Frame Contact Hoist Front Hoist Pads Note: The front hoist pads must not contact the rocker panels, the front fenders, or the floor pan. Position the front hoist pads under the front frame between the lower control arm and the frame pad. Rear Hoist Pads Note: The rear hoist pads must not contact the body rocker panels or the floor pan. Position the rear hoist pads under the rear spring, just behind the hanger Suspension Contact Hoist Front Lift Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 2668 Position the front lift under the outer edge of the front suspension lower control arms. Rear Lift Position the rear lift under the axle housing tubes on each side of the differential. Do not damage the stabilizer bar. Jacking When you are lifting a vehicle with a vehicle jack or a floor jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Under the Frame Rails Note: The floor jack pad must not contact rocker panel or the floor pan. Position the floor jack pad under the frame rail pad. Under the Rear Differential Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 2669 Position the floor jack pad under the center of the rear axle differential. Do not damage the establisher bar. Under the Rear Spring Hanger Position the jack under the rear spring hanger. Jack Stands When you support the vehicle with jack stands, place the jack stands under the frame, the front suspension crossmember, or the rear axle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Diagrams Valve Deactivation Solenoid: Diagrams Component Connector End Views Valve Lifter Oil Manifold (VLOM) Assembly (LMG, LC9, LZ1 or L96) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Diagrams > Page 2676 Valve Deactivation Solenoid: Description and Operation Cylinder Deactivation (Active Fuel Management) System Description To provide maximum fuel economy under light load driving conditions, the engine control module (ECM) will command the cylinder deactivation system ON to deactivate engine cylinders 1, 7, 6, and 4, switching to a V4 mode. The engine will operate on 8 cylinders, or V8 mode, during engine starting, engine idling, and medium to heavy throttle applications. When cylinder deactivation is commanded, the ECM will determine what cylinder is firing and begin deactivation on the next closest deactivated cylinder in firing order sequence. For example, if cylinder number 1 is on its combustion event when cylinder deactivation is commanded ON, the next cylinder in the firing order sequence that can be deactivated is cylinder number 7. If cylinder number 5 is on its combustion event when cylinder deactivation is commanded ON, then the next cylinder in the firing order sequence that can be deactivated is cylinder number 4. Cylinder deactivation is accomplished by not allowing the intake and exhaust valves to open on the selected cylinders by using special valve lifters. The deactivation lifters contain spring loaded locking pins that connect the internal pin housing of the lifter to the outer housing. The pin housing contains the lifter plunger and pushrod seat which interfaces with the pushrod. The outer housing contacts the camshaft lobe through a roller. During V8 mode, when all cylinders are active, the locking pins are pushed outward by spring force, locking the pin housing and outer housing together causing the lifter to function as a normal lifter. When cylinder deactivation is commanded ON, the locking pins are pushed inward with engine oil pressure directed from the valve lifter oil manifold (VLOM) assembly solenoids. When the lifter pin housing is unlocked from the outer housing, the pin housing will remain stationary, while the outer housing will move with the profile of the camshaft lobe, which results in the valve remaining closed. One VLOM solenoid controls both the intake and exhaust valves for each deactivating cylinder. There are 2 distinct oil passages going to each cylinder deactivation lifter bore, one for the hydraulic lash-adjusting feature of the lifter, and one for controlling the locking pins used for cylinder deactivation. Although both intake and exhaust valve lifters are controlled by the same solenoid in the VLOM, the intake and exhaust valves do not become deactivated at the same time. Cylinder deactivation is timed so that the cylinder is on an intake event. During an intake event, the intake cam lobe is pushing the valve lifter upwards to open the intake valve against the force of the valve spring. The force exerted by the valve spring is acting on the side of the lifter locking pins, preventing them from moving until the intake valve has closed. When the intake valve lifter reaches the base circle of the camshaft lobe, the valve spring force is reduced, allowing the locking pins to move, deactivating the intake valve. However, when cylinder deactivation is commanded ON, the exhaust valve for the deactivated cylinder is in the closed position, allowing the locking pins on the valve lifter to move immediately, and deactivate the exhaust valve. By deactivating the exhaust valve first, this allows the capture of a burnt air/fuel charge, or exhaust gas charge, in the combustion chamber. The capture Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Diagrams > Page 2677 of exhaust gases in the combustion chamber will contribute to a reduction in oil consumption, noise and vibration levels, and exhaust emissions when operating in V4 mode cylinder deactivation mode. During the transition from V8 to V4 mode, the fuel injectors will be turned OFF on the deactivated cylinders. To help prevent spark plug fouling, the ignition system secondary voltage or spark is still present across the spark plug electrodes on the deactivated cylinders. If all enabling conditions are met and maintained for cylinder deactivation operation, the ECM calibrations will limit cylinder deactivation to a cycle time of 10 minutes in V4 mode, then return to V8 mode for 1 minute. Switching between V8 and V4 modes is accomplished in less than 250 milliseconds, making the transitions seamless and transparent to the vehicle operator. The 250 milliseconds includes the time for the ECM to sequence the transitions, the response time for the VLOM solenoids to energize, and the time for the valve lifters to deactivate, all within 2 revolutions of the engine crankshaft. Valve Lifter Oil Manifold (VLOM) Assembly The cylinder deactivation system uses an electro-hydraulic actuator device called the valve lifter oil manifold (VLOM) assembly. The VLOM is bolted to the top of the engine valley, below the intake manifold assembly. The VLOM consists of 4 electrically operated normally closed solenoids. Each solenoid controls the application of engine oil pressure to the intake and exhaust valve lifters on the cylinders selected to deactivate. Engine oil pressure is routed to the VLOM assembly from an internal oil passage on the rear of the cylinder block. All 4 VLOM solenoids are connected in parallel to a fused ignition 1 voltage circuit, supplied by the powertrain relay. The ground or control circuit for each solenoid is connected to a low side driver internal to the engine control module (ECM). When all enabling conditions are met for cylinder deactivation, the ECM will ground each solenoid control circuit in firing order sequence, allowing current to flow through the solenoid windings. With the coil windings energized, the solenoid valve opens, redirecting engine oil pressure through the VLOM into 8 separate vertical passages in the engine lifter valley. The 8 vertical passages, 2 per cylinder, are connected to the valve lifter bores of the cylinders to be deactivated. When vehicle-operating conditions require a return to V8 mode, the ECM will turn OFF the control circuit for the solenoids, allowing the solenoid valves to close. With the solenoid valves closed, engine oil pressure in the control ports is exhausted through the body of the solenoids into the engine block lifter valley. The housing of the VLOM incorporates several bleeds in the oil passages to purge any air trapped in the VLOM or engine block. To help control contamination to the hydraulic circuits, a small replaceable oil screen is located in the VLOM oil inlet passage, below the oil pressure sensor. The oil pressure sensor is a 3-wire sensor which provides oil pressure information to the ECM. During service, use extreme care in keeping the VLOM assembly free of any contamination or foreign material. Cylinder deactivation may be inhibited for many reasons including the following: * Engine coolant temperature out of range for cylinder activation * Engine vacuum out of range * Brake booster vacuum out of range * Transmission gear incorrect or shift in progress * Accelerator pedal out of range or rate of pedal application to fast * Engine oil pressure and temperature out of range * Engine speed of range * Vehicle speed out of range * Minimum time in V8 mode not met * Maximum V4 mode time exceeded * Decel fuel cutoff active * Reduced engine power active * Torque management active * Catalytic converter over temperature protection active * Piston protection active, knock detected * Cylinder deactivation solenoid driver circuit faults Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Camshaft Position (CMP) Actuator System The camshaft position (CMP) actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation (EGR) control, a wider engine torque range, improved gas mileage, and improved engine idle stability. The CMP actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. For the 6.0 liter (LY6, L76) and the 6.2 liter (L92) engine, the Park position for the CMP actuator and camshaft is 8.5 degrees before top dead center (BTDC) or 17 crankshaft degrees BTDC. The engine control module (ECM) can only command the CMP actuator to retard the valve timing from the Park position or advance the valve timing back to the Park position. The total range of valve timing authority is 31 degrees camshaft rotation, or 62 degrees of crankshaft rotation. The control range is from the Park position of 8.5 degrees camshaft or 17 degrees crankshaft BTDC, to 22.5 degrees camshaft or 45 degrees crankshaft after top dead center (ATDC). CMP Actuator System Operation The camshaft position (CMP) actuator system is controlled by the control module. The control module sends a pulse width modulated 12-volt signal to a CMP actuator solenoid in order to control the amount of engine oil flow to a camshaft actuator passage. There are 2 different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The camshaft actuator is attached to the front of the camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position (CKP). Incorrect engine oil pressure (EOP), viscosity, temperature, engine oil level, or aftermarket engine oil additives can have an adverse affect on camshaft phaser performance. CMP Actuator Solenoid Circuit Diagnostics The engine control module (ECM) monitors the control circuit of the camshaft position (CMP) actuator solenoid for electrical faults. The control module has the ability to determine if a control circuit is open, shorted high, or shorted low. If the control module detects a fault with the CMP actuator solenoid control circuit, DTC P0010 will set. CMP Actuator System Performance Diagnostic The engine control module (ECM) monitors the performance of the camshaft position (CMP) actuator system by monitoring the calibrated desired position and the actual position of the camshaft through the 4X signal of the CMP sensor. If the difference between the actual and desired position is Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Page 2681 greater than a calibrated angle for a calibrated amount of time, DTC P0011 will set. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2685 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gauge at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Position (CMP) Actuator Solenoid Valve - First Pass...................................................................................................................65 Nm (48 lb ft.) Camshaft Position (CMP) Actuator Solenoid Valve - Final Pass............................................................................................................................90 degrees Camshaft Retainer Bolts - Hex Head Bolts.......................................................................................... ..........................................................25 Nm (18 lb ft.) Camshaft Retainer Bolts - TORX Head Bolts................................................................................................................................................15 Nm (11 lb ft.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation Camshaft: Description and Operation Camshaft Position Actuator and Solenoid Valve Description Camshaft The camshaft is designed to provide a lubrication path for pressurized engine oil to flow to the camshaft position (CMP) actuator. Pressurized engine oil enters the camshaft at bearing journal location number 2. Oil travels through the camshaft, out the front, and into the CMP actuator solenoid valve. CMP Actuator Solenoid Valve The CMP actuator solenoid valve consists of a housing, spool valve (1), spool return spring (2), oil filter (3), inlet check ball return spring (4), and inlet check ball (5). Pressurized engine oil enters the valve and travels through the filter to the spool. Spool position is controlled by the CMP magnet and engine control module (ECM). When the spool is moved to the proper position, oil flow is directed through the valve and into the CMP actuator assembly. The CMP solenoid valve is a torque-to-yield design and should be replaced each time it is removed. CMP Actuator Magnet Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Page 2695 The CMP actuator magnet (752) is located in the engine front cover and is sealed by a gasket (753). The CMP actuator magnet is controlled by a 12-volt 150 Hz pulse width 0-100 percent duty cycle signal from the ECM. When energized, the solenoid uses electromagnetic force on the magnet pintle to position the spool valve of the CMP solenoid valve. CMP Actuator The CMP actuator is a vane type design that hydraulically changes angle or timing of the camshaft relative to crankshaft position. The CMP actuator allows earlier or later intake and exhaust valve opening during the 4-stroke engine cycle. The CMP actuator cannot vary the duration of valve opening or valve lift. The CMP actuator is to be serviced as an assembly. For system operation, refer to Camshaft Actuator System Description (See: Powertrain Management/Computers and Control Systems/Description and Operation/Camshaft Actuator System). The CMP actuator consists of the CMP reluctor wheel (1), wheel retaining pins (2), return spring (3), front cover (4), park position pin (5), park position pin spring (6), vanes and vane springs (7), rotor (8), housing with chain sprocket (9), sealing cover/thrust plate (10), and bolts (11). CMP System Operation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Page 2696 A CMP actuator dynamically changes valve timing events relative to piston timing by controlling camshaft position. This is sometimes referred to as variable valve timing or camshaft phasing. Variable valve timing or camshaft phasing does not change duration or lift. * By advancing camshaft timing, an improvement in low end torque can be achieved. * By retarding camshaft timing slightly, an improvement in high end power can be achieved. * By retarding camshaft timing significantly, an improvement in light load fuel economy can be achieved. There are 5 cavities divided by vanes within the CMP actuator. * When oil is directed to the advance cavities (1), the camshaft timing is advanced. * When oil is directed to the retard cavities (2), the camshaft timing is retarded. * When oil is directed to both cavities, the camshaft is held stationary. The CMP actuator has a 52 degree range of authority. With the engine not running and no engine oil pressure to the CMP actuator, the high tension spring positions camshaft timing at the 7 degree advanced park position. During normal engine operation, and based on performance requirements, the ECM may adjust camshaft timing, as required, within a range from 7 degrees advanced to 45 degrees retard. CMP System Lubrication Flow and Actuator Operation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Page 2697 1. Oil enters the camshaft at the second main bearing journal (1). 2. Oil travels through the camshaft into the CMP actuator valve check ball (2) and filter (3). 3. Oil exits the valve and travels through the internal passages of the camshaft (4). 4. Oil exits the camshaft and enters the actuator oil entry ports. 5. Oil travels through the actuator and is directed back into the valve (5). 6. Valve spool position directs oil to the advance or retard passages of the actuator. The valve may also, under certain conditions, be positioned in a neutral position with no flow to either the advance or retard passages of the actuator. 1. Oil flows from the camshaft into the valve inlet (3) through the internal check ball and filter. 2. Oil exits the valve (2) and travels within the internal passages of the camshaft into the entry ports (7) of the actuator. 3. The center oil groove of the actuator is pressurized and oil reenters the valve (1). 4. Valve spool position directs oil out of the valve advance (5) or retard (4) ports to the actuator. The valve may also, under certain conditions, be positioned in a neutral position with no flow to either the advance or retard passages of the actuator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Page 2698 1. Pressurized oil enters the retard cavities (2) of the actuator and moves the park pin (3) from the locked position. 2. As pressure increases within the retard cavities (2), the rotor and camshaft rotate counter clockwise retarding valve timing. 3. As the duty cycle decreases, the spool is repositioned and oil is sent to the advance cavities (1), rotating the rotor and camshaft clockwise, advancing valve timing. * With a 0 percent duty cycle signal to the magnet, the spool is positioned in the fully extended position and there is full flow to the advance cavities of the actuator. As duty cycle increases to near 50 percent, flow to the advance cavities is decreased. * With a 50 percent duty cycle, the spool is positioned neutral, with no flow to either the advance and retard cavities. * With a 51-100 percent duty cycle, the spool is positioned to provide oil flow to retard cavities. As the duty cycle increases, the flow to retard cavities increases. * With a 100 percent duty cycle, there is full flow to the retard cavities of the actuator. * The above duty cycle percentage values are only a guideline, as the actual duty cycle values may vary based on engine oil temperature, solenoid magnet coil temperature, magnet coil resistance, and other specifics. CMP Actuator Park Position Verification Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Page 2699 The CMP actuator can be visually inspected to determine if the tension spring has returned the reluctor wheel and rotor to the park position. With the reluctor wheel returned to the proper parked position, the edge of the notched area of the wheel (2) aligns with the marking (1) on the camshaft sprocket. CMP Actuator Handling Safety Warning: Refer to Camshaft Position Actuator Removal and Installation Warning (See: Powertrain Management/Computers and Control Systems/Camshaft Position Sensor/Service Precautions). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Page 2700 Install tie wrap (1) to retain the reluctor wheel to the sprocket. The reluctor wheel is mounted to the actuator body with 3 roll pins. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement Camshaft: Service and Repair Camshaft Replacement Camshaft Replacement Special Tools * EN 46330 Timing Belt Tensioner Retaining Pin * EN 46330 Angle Meter Removal Procedure 1. Remove the radiator support. Refer to Radiator Support Replacement (See: Body and Frame/Radiator Support/Service and Repair/Radiator Support Replacement) 2. Remove the valve lifters. Refer to Valve Lifter Replacement (With AFM) (See: Lifter / Lash Adjuster/Service and Repair/Valve Lifter Replacement (With AFM))Valve Lifter Replacement (With out AFM) (See: Lifter / Lash Adjuster/Service and Repair/Valve Lifter Replacement (With out AFM)) 3. Remove the Timing Chain, Camshaft Position Actuator, and Solenoid Valve. Refer to Timing Chain, Crankshaft Sprocket, Camshaft Position Actuator, and Solenoid Valve Replacement (See: Timing Components/Timing Chain/Service and Repair) 4. Remove the camshaft retainer bolts (204) and retainer (203). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 2703 Caution: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 5. Install a bolt into the camshaft. 6. Using the bolt as a handle, carefully rotate and pull the camshaft out of the engine block. 7. Clean and inspect the camshaft and bearings. Refer to Camshaft and Bearings Cleaning and Inspection (See: Service and Repair/Overhaul/25. Camshaft and Bearings Cleaning and Inspection). Installation Procedure Note: If camshaft replacement is required, the valve lifters must also be replaced. 1. Lubricate the camshaft journals and the bearings with clean engine oil. Caution: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 2704 2. Using the bolt as a handle, carefully install the camshaft into the engine block. 3. Remove the bolt from the front of the camshaft. Note: Install the retainer with the sealing gasket facing the engine block. The gasket surface on the engine block should be clean and free of dirt and/or debris. 4. Install the camshaft retainer (203) and bolts (204). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the camshaft retainer bolts. * Tighten the first design hex head bolts (3) to 25 Nm (18 lb ft). * Tighten the second design TORX(R) head bolts (4) to 15 Nm (11 lb ft). 6. Install the Timing Chain, Camshaft Position Actuator, and Solenoid Valve. Refer to Timing Chain, Crankshaft Sprocket, Camshaft Position Actuator, and Solenoid Valve Replacement (See: Timing Components/Timing Chain/Service and Repair) 7. Install the valve lifters. Refer to Valve Lifter Replacement (With AFM) (See: Lifter / Lash Adjuster/Service and Repair/Valve Lifter Replacement (With AFM))Valve Lifter Replacement (With out AFM) (See: Lifter / Lash Adjuster/Service and Repair/Valve Lifter Replacement (With out AFM)). 8. Install the radiator support. Refer to Radiator Support Replacement (See: Body and Frame/Radiator Support/Service and Repair/Radiator Support Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 2705 Camshaft: Service and Repair Camshaft Position Actuator Magnet Replacement Camshaft Position Actuator Magnet Replacement Removal Procedure 1. Remove the water pump. Refer to Water Pump Replacement (LU3) (See: Water Pump/Service and Repair)Water Pump Replacement (LMM) ( See: Water Pump/Service and Repair)Water Pump Replacement (V8) (See: Water Pump/Service and Repair). 2. Disconnect the engine harness electrical connector from the camshaft position (CMP) actuator magnet. 3. Remove the CMP actuator magnet bolts (751) and magnet (752). 4. Remove and discard the CMP actuator magnet gasket (753). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 2706 Note: The gasket surface should be free of oil or other foreign material during assembly. 1. Install a NEW CMP actuator magnet gasket (753) onto the CMP actuator magnet. 2. Install the CMP actuator magnet (752) to the front cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP actuator magnet bolts (751) and tighten to 12 Nm (106 lb in). 4. Connect the engine harness electrical connector to the CMP actuator magnet. 5. Install the water pump. Refer to Water Pump Replacement (LU3) (See: Water Pump/Service and Repair)Water Pump Replacement (LMM) ( See: Water Pump/Service and Repair)Water Pump Replacement (V8) (See: Water Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 2707 Camshaft: Service and Repair Camshaft Position Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Special Tools * J 42386-A Flywheel Holding Tool * J 45059 Angle Meter Removal Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the J 42386-A (1) and bolts. Use 1 M10 - 1.5 x 120 mm and 1 M10 - 1.5 x 45 mm bolt for proper tool operation. Tighten the J 42386-A bolts to 50 Nm (37 lb ft). 2. Remove the camshaft position (CMP) actuator magnet. Refer to Camshaft Position Actuator Magnet Replacement (See: Camshaft Position Actuator Magnet Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 2708 Warning: Refer to Camshaft Position Actuator Removal and Installation Warning (See: Powertrain Management/Computers and Control Systems/Camshaft Position Sensor/Service Precautions). 3. Remove the CMP actuator solenoid valve (234). 4. Discard the solenoid valve. Installation Procedure 1. Install a NEW CMP actuator solenoid valve (234). With the CMP actuator properly positioned onto the camshaft, the CMP actuator solenoid valve can be threaded completely into the camshaft using light hand pressure. Tighten by hand until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 2709 2. Tighten the CMP actuator solenoid valve. 1. Tighten the CMP actuator solenoid valve a first pass to 65 Nm (48 lb ft). 2. Tighten the CMP actuator solenoid valve a final pass an additional 90 degrees using the J 45059 . 3. Remove the J 42386-A (1). 4. Install the CMP actuator magnet. Refer to Camshaft Position Actuator Magnet Replacement (See: Camshaft Position Actuator Magnet Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 2710 Camshaft: Service and Repair Camshaft Position Actuator Replacement Camshaft Position Actuator Replacement Special Tools * EN 46330 Timing Belt Tensioner Retaining Pin * J 45059 Angle Meter Removal Procedure 1. Remove the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil Pump/Service and Repair). 2. Remove and discard the camshaft position (CMP) actuator solenoid valve (234). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 2711 Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. 3. Loosen and separate the CMP actuator and timing chain from the camshaft. Position your fingers behind the actuator sprocket and pull the actuator away from the front of the camshaft. Never pull on the reluctor wheel when attempting to remove the actuator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 2712 4. Remove the CMP actuator (235) and timing chain (208). 5. Insert and secure a tie strap (1) through the center of the actuator and over the reluctor wheel. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 2713 1. Compress the timing chain tensioner guide and install the EN 46330 . Note: * Properly locate the CMP actuator on the locating pin of the camshaft. * The sprocket teeth and timing chain must mesh. * The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. * DO NOT use the CMP solenoid valve again. Install a NEW valve during assembly. 2. Identify the alignment hole (1) in the rear face of the CMP actuator and the locating pin (2) on the front face of the camshaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 2714 Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. 3. Install the CMP actuator and timing chain. Align the hole in the rear face of the CMP actuator with the locating pin on the front face of the camshaft. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks. Use care to install the actuator completely onto the front of the camshaft. Position your fingers onto the face of the actuator sprocket and push the actuator onto the front of the camshaft. Never push on the reluctor wheel when attempting to install the actuator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 2715 4. Place a straight edge across the front face of the engine block and inspect for proper installation of the CMP actuator and timing chain. With the CMP actuator properly and completely installed onto the front of the camshaft, the timing chain will not protrude beyond the front face of the engine block. 5. Install a NEW CMP actuator solenoid valve (234). With the CMP actuator properly positioned onto the camshaft, the CMP actuator solenoid valve can be threaded completely into the camshaft using light hand pressure. Tighten by hand until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 2716 6. Inspect the sprockets for proper alignment. The mark on the CMP actuator sprocket (1) should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. 7. Remove the EN 46330 . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 2717 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Tighten the CMP actuator solenoid valve. 1. Tighten the valve a first pass to 65 Nm (48 lb ft). 2. Tighten the valve a final pass and additional 90 degrees using J 45059 . 9. Install the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest for Lifter / Lash Adjuster: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up Lifter / Lash Adjuster: Customer Interest Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest for Lifter / Lash Adjuster: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 2726 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash Adjuster: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up Lifter / Lash Adjuster: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash Adjuster: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 2732 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement Lifter / Lash Adjuster: Service and Repair Valve Lifter Oil Filter Replacement Valve Lifter Oil Filter Replacement Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. Remove the oil pressure sensor (1) and washer (2). 4. Remove and discard the valve lifter oil filter (3). 5. Remove and discard the valve lifter oil filter O-ring seal (4). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 2735 1. Install a NEW valve lifter oil filter O-ring seal (4) into the valve lifter oil manifold. 2. Install the NEW valve lifter oil filter (3). 3. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the oil pressure sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the oil pressure sensor washer (2) and sensor (1). Tighten the sensor to 35 Nm (26 lb ft). 5. Connect the engine harness electrical connector (1) to the oil pressure sensor. 6. Install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 2736 Lifter / Lash Adjuster: Service and Repair Valve Lifter Oil Manifold Replacement Valve Lifter Oil Manifold Replacement Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. DO NOT lift the valve lifter oil manifold by the electrical lead frame. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 2737 4. Remove the valve lifter oil manifold bolts (2). 5. Remove the valve lifter oil manifold (1). Note: Remove only the outer gasket from the manifold. Do not disassemble any of the internal components of the manifold in an attempt to remove the 8 inner sealing gaskets. If the inner gaskets are cut or damaged, replace the manifold as an assembly. Only use a wire-cutter type tool in order to minimize the amount of debris. Do not use a rotary-type cutting tool on the retaining straps. 6. Identify the 8 gasket retaining strap locations (1-8). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 2738 7. Using a cutter type tool, cut the 8 retaining straps. 8. Remove the outer gasket (1) from the valve lifter oil manifold. Installation Procedure Note: All gasket surfaces should be free of oil or other foreign material during assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 2739 1. Place the service gasket (1) onto the valve lifter oil manifold. 2. Install the valve lifter oil manifold (1) to the engine. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the valve lifter oil manifold bolts (2). Tighten the bolts to 25 Nm (18 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 2740 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. 5. Install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 2741 Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement (With AFM) Valve Lifter Replacement (With AFM) Removal Procedure 1. Remove the cylinder head and gasket. Refer to Cylinder Head Replacement - Left Side (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement) or Cylinder Head Replacement - Right Side (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement). 2. Remove the valve lifter guide bolts (211). 3. Remove the valve lifter guides (210) with the lifters. Note the installed position of the guides. The notched area of the guides is to align with the locating tab on the engine block. 4. Remove the valve lifters (209, 219) from the guide (210). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 2742 Note: The active fuel management lifters are installed into the guide by aligning the notched area of the guide (1) with the raised surface on the side of the lifter (2). 5. Organize or mark the components so that they can be installed in the same location from which they were removed, if required. 6. Clean and inspect the valve lifters, if required. Refer to Valve Lifter and Guide Cleaning and Inspection (See: Service and Repair/Overhaul/30. Valve Lifter and Guide Cleaning and Inspection). Installation Procedure Note: * When reusing valve lifters, install the lifters to their original locations. * Each of the 4 valve guide assemblies will contain 2 active fuel management valve lifters and 2 non active fuel management valve lifters. * With the lifters and guides properly installed, cylinders 1, 4, 6, and 7 lifter bores will each contain 2 active fuel management valve lifters. 1. Lubricate the valve lifters (209, 219) and engine block valve lifter bores with clean engine oil. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 2743 2. Insert the valve lifters into the lifter guides. * Align the flat area (3) on the top of the non active fuel management lifter with the flat area in the lifter guide bore. Push the lifter completely into the guide bore. * The active fuel management lifters are to be installed into the guide, with the notch in the guide (1) aligned with the raised area (2) of the lifter. 3. Install the valve lifters and guide (210) to the engine block. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the valve lifter guide bolts (211). Tighten the bolt to 12 Nm (106 lb in). 5. Install the cylinder head and gasket. Refer to Cylinder Head Replacement - Left Side (See: Cylinder Head Assembly/Service and Repair/Cylinder Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 2744 Head Replacement) or Cylinder Head Replacement - Right Side (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 2745 Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement (With out AFM) Valve Lifter Replacement (With out AFM) Removal Procedure 1. Remove the cylinder head and gasket. Refer to Cylinder Head Replacement - Left Side (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement) or Cylinder Head Replacement - Right Side (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement). 2. Remove the valve lifter guide bolts (211). 3. Remove the valve lifter guides (210) with the lifters. Note the installed position of the guides. The notched area of the guides is to align with the locating tab on the engine block. 4. Remove the valve lifters (209) from the guide (210). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 2746 5. Organize or mark the components so that they can be installed in the same location from which they were removed, if required. 6. Clean and inspect the valve lifters, if required. Refer to Valve Lifter and Guide Cleaning and Inspection (See: Service and Repair/Overhaul/30. Valve Lifter and Guide Cleaning and Inspection). Installation Procedure Note: When reusing valve lifters, install the lifters to their original locations. 1. Lubricate the valve lifters (209) and engine block valve lifter bores with clean engine oil. 2. Insert the valve lifters into the lifter guides (210). Align the flat area on the top of the lifter with the flat area in the lifter guide bore. Push the lifter completely into the guide bore. 3. Install the valve lifters and guide (210) to the engine block. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Lifter Oil Filter Replacement > Page 2747 4. Install the valve lifter guide bolts. Tighten the bolt to 12 Nm (106 lb in). 5. Install the cylinder head and gasket. Refer to Cylinder Head Replacement - Left Side (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement) or Cylinder Head Replacement - Right Side (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair Push Rod: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side). Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. 2. Remove the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). Note: Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 3. Remove the rocker arm bolts. 4. Remove the rocker arms. 5. Remove the rocker arm pivot support. 6. Remove the pushrods. 7. Clean and inspect the rocker arms and pushrods, if required. Refer to Valve Rocker Arm and Push Rod Cleaning and Inspection (See: Service Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 2751 and Repair/Overhaul/29. Valve Rocker Arm and Push Rod Cleaning and Inspection). Installation Procedure Note: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. 1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the rocker arm. 3. Install the rocker arm pivot support. Note: Make sure that the pushrods seat properly to the valve lifter sockets. 4. Install the pushrods. Note: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. 5. Install the rocker arms and bolts. Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinders 2, 4, 6 and 8 are the right bank. 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, the number one cylinder rocker arms will be off lobe lift. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 2752 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. With the engine in the number one firing position, tighten the following rocker arm bolts: * Tighten cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 Nm (22 lb ft). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts: * Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 lb ft). 10. Install the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 11. Install the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side). Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. 2. Remove the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). Note: Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 3. Remove the rocker arm bolts. 4. Remove the rocker arms. 5. Remove the rocker arm pivot support. 6. Remove the pushrods. 7. Clean and inspect the rocker arms and pushrods, if required. Refer to Valve Rocker Arm and Push Rod Cleaning and Inspection (See: Service Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 2756 and Repair/Overhaul/29. Valve Rocker Arm and Push Rod Cleaning and Inspection). Installation Procedure Note: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. 1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the rocker arm. 3. Install the rocker arm pivot support. Note: Make sure that the pushrods seat properly to the valve lifter sockets. 4. Install the pushrods. Note: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. 5. Install the rocker arms and bolts. Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinders 2, 4, 6 and 8 are the right bank. 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, the number one cylinder rocker arms will be off lobe lift. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 2757 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. With the engine in the number one firing position, tighten the following rocker arm bolts: * Tighten cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 Nm (22 lb ft). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts: * Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 lb ft). 10. Install the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 11. Install the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Camshaft Position (CMP) Actuator System The camshaft position (CMP) actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation (EGR) control, a wider engine torque range, improved gas mileage, and improved engine idle stability. The CMP actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. For the 6.0 liter (LY6, L76) and the 6.2 liter (L92) engine, the Park position for the CMP actuator and camshaft is 8.5 degrees before top dead center (BTDC) or 17 crankshaft degrees BTDC. The engine control module (ECM) can only command the CMP actuator to retard the valve timing from the Park position or advance the valve timing back to the Park position. The total range of valve timing authority is 31 degrees camshaft rotation, or 62 degrees of crankshaft rotation. The control range is from the Park position of 8.5 degrees camshaft or 17 degrees crankshaft BTDC, to 22.5 degrees camshaft or 45 degrees crankshaft after top dead center (ATDC). CMP Actuator System Operation The camshaft position (CMP) actuator system is controlled by the control module. The control module sends a pulse width modulated 12-volt signal to a CMP actuator solenoid in order to control the amount of engine oil flow to a camshaft actuator passage. There are 2 different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The camshaft actuator is attached to the front of the camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position (CKP). Incorrect engine oil pressure (EOP), viscosity, temperature, engine oil level, or aftermarket engine oil additives can have an adverse affect on camshaft phaser performance. CMP Actuator Solenoid Circuit Diagnostics The engine control module (ECM) monitors the control circuit of the camshaft position (CMP) actuator solenoid for electrical faults. The control module has the ability to determine if a control circuit is open, shorted high, or shorted low. If the control module detects a fault with the CMP actuator solenoid control circuit, DTC P0010 will set. CMP Actuator System Performance Diagnostic The engine control module (ECM) monitors the performance of the camshaft position (CMP) actuator system by monitoring the calibrated desired position and the actual position of the camshaft through the 4X signal of the CMP sensor. If the difference between the actual and desired position is Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Page 2761 greater than a calibrated angle for a calibrated amount of time, DTC P0011 will set. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > 6.0L RPO L96 VIN G Connecting Rod Bearing: Specifications 6.0L RPO L96 VIN G Connecting Rod Connecting Rod Bearing Clearance Production...........................................................................................................0.023-0.065 mm (0.0009-0.0025 in.) Connecting Rod Bearing Clearance Service...................................................................................................................0.023-0.076 mm (0.0009-0.003 in.) Connecting Rod Bore Diameter - Bearing End...............................................................................................................56.505-56.525 mm (2.224-2.225 in.) Connecting Rod Bore Out-of-Round - Bearing End Production................................................................................0.004-0.008 mm (0.00015-0.0003 in.) Connecting Rod Bore Out-of-Round - Bearing End Service......................................................................................0.004-0.008 mm (0.00015-0.0003 in.) Connecting Rod Side Clearance.......................................................................................................... .................................0.11-0.51 mm (0.00433-0.02 in.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > 6.0L RPO L96 VIN G > Page 2767 Connecting Rod Bearing: Specifications 6.0L LY6 VIN K Connecting Rod Bearing Clearance Production...........................................................................................................0.023-0.065 mm (0.0009-0.0025 in.) Connecting Rod Bearing Clearance Service...................................................................................................................0.023-0.076 mm (0.0009-0.003 in.) Connecting Rod Bore Diameter - Bearing End...............................................................................................................56.505-56.525 mm (2.224-2.225 in.) Connecting Rod Bore Out-of-Round - Bearing End - Production.............................. .......................................................................................................................................0.004-0.008 mm (0.00015-0.0003 in.) Connecting Rod Bore Out-of-Round - Bearing End - Service...................... ....................................................................................................................................................0.004 -0.008 mm (0.00015-0.0003 in.) Connecting Rod Side Clearance....................................................... ....................................................................................0.11-0.51 mm (0.00433-0.02 in.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > 6.0L RPO L96 VIN G Connecting Rod: Specifications 6.0L RPO L96 VIN G Connecting Rod Connecting Rod Bearing Clearance Production...........................................................................................................0.023-0.065 mm (0.0009-0.0025 in.) Connecting Rod Bearing Clearance Service...................................................................................................................0.023-0.076 mm (0.0009-0.003 in.) Connecting Rod Bore Diameter - Bearing End...............................................................................................................56.505-56.525 mm (2.224-2.225 in.) Connecting Rod Bore Out-of-Round - Bearing End Production................................................................................0.004-0.008 mm (0.00015-0.0003 in.) Connecting Rod Bore Out-of-Round - Bearing End Service......................................................................................0.004-0.008 mm (0.00015-0.0003 in.) Connecting Rod Side Clearance.......................................................................................................... .................................0.11-0.51 mm (0.00433-0.02 in.) Connecting Rod Bolts - First Pass.................. ................................................................................................................................................20 Nm (15 lb ft.) Connecting Rod Bolts - Final Pass........................................................................................ ...................................................................................85 degrees Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > 6.0L RPO L96 VIN G > Page 2772 Connecting Rod: Specifications 6.0L LY6 VIN K Connecting Rod Bearing Clearance Production...........................................................................................................0.023-0.065 mm (0.0009-0.0025 in.) Connecting Rod Bearing Clearance Service...................................................................................................................0.023-0.076 mm (0.0009-0.003 in.) Connecting Rod Bore Diameter - Bearing End...............................................................................................................56.505-56.525 mm (2.224-2.225 in.) Connecting Rod Bore Out-of-Round - Bearing End - Production.............................. .......................................................................................................................................0.004-0.008 mm (0.00015-0.0003 in.) Connecting Rod Bore Out-of-Round - Bearing End - Service...................... ....................................................................................................................................................0.004 -0.008 mm (0.00015-0.0003 in.) Connecting Rod Side Clearance....................................................... ....................................................................................0.11-0.51 mm (0.00433-0.02 in.) Connecting Rod Bolts - First Pass........................................................................................................................... .......................................20 Nm (15 lb ft.) Connecting Rod Bolts - Final Pass..................................... ......................................................................................................................................85 degrees Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > 6.0L RPO L96 VIN G Crankshaft Main Bearing: Specifications 6.0L RPO L96 VIN G Crankshaft Main Bearing Bore Diameter.............................................................................................. ............................69.871-69.889 mm (2.75-2.751 in.) Crankshaft Main Bearing Bore Out-of-Round.. .....................................................................................................................................0.006 mm (0.0002 in.) Crankshaft Main Bearing Clearance Production............................................................................................................0.02-0.052 mm (0.0008-0.0021 in.) Crankshaft Main Bearing Clearance Service..................................................................................................................0.02-0.065 mm (0.0008-0.0025 in.) NEW Crankshaft Bearing Cap Bolts M8 Bolts (1-5) - First Pass in Sequence............................................................................................... ..........................................................20 Nm (15 lb ft.) M8 Bolts (1-5) - Second Pass in Sequence..... ...............................................................................................................................................30 Nm (22 lb ft.) M8 Bolts (6-10) - First Pass in Sequence.............................................................................. .........................................................................20 Nm (15 lb ft.) M8 Bolts (6-10) - Second Pass in Se quence.................................................................................................................................................. 30 Nm (22 lb ft.) M10 Bolts - First Pass in Sequence........................................................................... .....................................................................................20 Nm (15 lb ft.) M10 Bolts - Final Pass in Se quence.................................................................................................................................................. .......................80 degrees M10 Studs - First Pass in Sequence.......................................................... .....................................................................................................20 Nm (15 lb ft.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > 6.0L RPO L96 VIN G > Page 2777 M10 Studs - Final Pass in Sequence................................................................................................... .....................................................................51 degrees Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > 6.0L RPO L96 VIN G > Page 2778 Crankshaft Main Bearing: Specifications 6.0L LY6 VIN K Crankshaft Main Bearing Bore Diameter.............................................................................................. ............................69.871-69.889 mm (2.75-2.751 in.) Crankshaft Main Bearing Bore Out-of-Round.. .....................................................................................................................................0.006 mm (0.0002 in.) Crankshaft Main Bearing Clearance Production............................................................................................................0.02-0.052 mm (0.0008-0.0021 in.) Crankshaft Main Bearing Clearance Service..................................................................................................................0.02-0.065 mm (0.0008-0.0025 in.) NEW Crankshaft Bearing Cap Bolts M8 Bolts (1-5) - First Pass in Sequence............................................................................................... ..........................................................20 Nm (15 lb ft.) M8 Bolts (1-5) - Second Pass in Sequence..... ...............................................................................................................................................30 Nm (22 lb ft.) M8 Bolts (6-10) - First Pass in Sequence.............................................................................. .........................................................................20 Nm (15 lb ft.) M8 Bolts (6-10) - Second Pass in Se quence.................................................................................................................................................. 30 Nm (22 lb ft.) M10 Bolts - First Pass in Sequence........................................................................... .....................................................................................20 Nm (15 lb ft.) M10 Bolts - Final Pass in Se quence.................................................................................................................................................. .......................80 degrees M10 Studs - First Pass in Sequence.......................................................... .....................................................................................................20 Nm (15 lb ft.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > 6.0L RPO L96 VIN G > Page 2779 M10 Studs - Final Pass in Sequence................................................................................................... .....................................................................51 degrees Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Housing Replacement Special Tools * J-41476 - Front and Rear Cover Alignment Tool * J-41479-2A - Crankshaft Rear Oil Seal Installation Guide Removal Procedure 1. Remove the automatic transmission flexplate. Refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair). 2. Remove the oil pan-to-rear oil seal housing bolts (1). 3. Remove the rear oil seal housing bolts (1). 4. Remove the rear oil seal housing (2) and gasket (3). Discard the gasket. 5. Remove and discard the rear oil seal (4). Installation Procedure Note: * Do not reuse the crankshaft oil seal or rear cover gasket. * Do not apply any type of sealant to the rear cover gasket, unless specified. * The special tool in this procedure is used to properly center the crankshaft rear oil seal. * All gasket surfaces should be free of oil or other foreign material during assembly. * The crankshaft rear oil seal MUST be centered in relation to the crankshaft. * An improperly aligned rear cover may cause premature rear oil seal wear and/or engine assembly oil leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Page 2783 1. Apply a 5 mm (0.2 in) bead of sealant, 20 mm (0.8 in) to the 2 joints (a) at the rear of the block/pan. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). 2. Inspect the rear oil gallery plug for proper installation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Page 2784 Installation Procedure - Cover with Seal 1. Install the J-41479-2A - guide cone and bolts onto the rear of the crankshaft. 2. Install the NEW rear housing gasket (1), rear housing with seal (2), rear housing-to-engine bolts (3) and oil pan-to-rear housing bolts (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the rear housing-to-engine bolts (3) until snug. Do not overtighten. 4. Tighten the oil pan-to-rear housing bolts (4) to 12 Nm (106 lb in). 5. Tighten the rear housing-to-engine bolts (3) to 30 Nm (22 lb ft). 6. Remove the J-41479-2A - guide. 7. Install the automatic transmission flexplate. Refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair). Installation Procedure - Cover without Seal Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Page 2785 1. Position a NEW rear oil seal housing gasket (3) and the housing (2) to the engine. 2. Install the rear oil seal housing bolts (1) until snug. Do not overtighten. 3. Rotate the crankshaft until 2 opposing flywheel bolts holes are parallel to the oil pan surface. Note: The tapered legs of the alignment tool must enter the rear cover oil seal bore. 4. Install the J-41476 - tool and bolts onto the rear of the crankshaft. 5. Tighten the J-41476 - tool bolts until snug. Do not overtighten. 6. Install the oil pan-to-rear oil seal housing bolts (1). 1. Tighten the oil pan-to-rear cover bolts to 12 Nm (106 lb in). 2. Tighten the rear oil seal housing-to-engine bolts to 30 Nm (22 lb ft). 7. Remove the J-41476 - tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Page 2786 8. Install a NEW crankshaft rear oil seal. Refer to Crankshaft Rear Oil Seal Replacement (See: Seals and Gaskets/Crankshaft Main Bearing Seal/Service and Repair). 9. Install the automatic transmission flexplate. Refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > 6.0L RPO L96 VIN G Crankshaft: Specifications 6.0L RPO L96 VIN G Crankshaft Connecting Rod Journal Diameter Production.........................................................................................................53.318-53.338 mm (2.0991-2.0999 in.) Connecting Rod Journal Diameter Service.......................................................................................................................................53.308 mm (2.0987 in.) Connecting Rod Journal Out-of-Round Production............................................................................................................................0.005 mm (0.0002 in.) Connecting Rod Journal Out-of-Round Service....................................................................................................................................0.01 mm (0.0004 in.) Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Production.......... ........................................................................................................................................................0.0 05 mm (0.0002 in.) Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Service... .............................................................................................................................................................. .......0.02 mm (0.00078 in.) Crankshaft End Play.................................................................................. ...........................................................................0.04-0.2 mm (0.0015-0.0078 in.) Crankshaft Main Bearing Clearance Production............................................................................................................0.02-0.052 mm (0.0008-0.0021 in.) Crankshaft Main Bearing Clearance Service..................................................................................................................0.02-0.065 mm (0.0008-0.0025 in.) Crankshaft Main Journal Diameter Production............................................................................................................64.992-65.008 mm (2.558-2.559 in.) Crankshaft Main Journal Diameter - Service............................................................ .............................................................................64.992 mm (2.558 in.) Crankshaft Main Journal Out-of-Round Production.......................................................................................................................0.003 mm (0.000118 in.) Crankshaft Main Journal Out-of-Round Service.................................................................................................................................0.008 mm (0.0003 in.) Crankshaft Main Journal Taper - Production..................................................................... .....................................................................0.01 mm (0.0004 in.) Crankshaft Main Journal Taper Service..............................................................................................................................................0. 02 mm (0.00078 in.) Crankshaft Rear Flange Runout.......................................................................... .......................................................................................0.05 mm (0.002 in.) Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 in) Below Tooth Diameter....................................................... ...................................................................................................0.7 mm (0.028 in.) Crankshaft Thrust Surface - Production............................................................................................................................ 26.14-26.22 mm (1.029-1.0315 in.) Crankshaft Thrust Surface - Service............................................ ..........................................................................................................26.22 mm (1.0315 in.) Crankshaft Thrust Surface Runout....................................................................................................... ...................................................0.025 mm (0.001 in.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > 6.0L RPO L96 VIN G > Page 2791 Crankshaft: Specifications 6.0L LY6 VIN K Crankshaft Connecting Rod Journal Diameter Production.........................................................................................................53.318-53.338 mm (2.0991-2.0999 in.) Connecting Rod Journal Diameter Service.......................................................................................................................................53.308 mm (2.0987 in.) Connecting Rod Journal Out-of-Round Production............................................................................................................................0.005 mm (0.0002 in.) Connecting Rod Journal Out-of-Round Service....................................................................................................................................0.01 mm (0.0004 in.) Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Production.......... .............................................................................................................................................................. .....................0.005 mm (0.0002 in.) Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Service................................................................................................................................... ................................................................0.02 mm (0.00078 in.) Crankshaft End Play......................... ....................................................................................................................................0.04-0.2 mm (0.0015-0.0078 in.) Crankshaft Main Bearing Clearance Production............................................................................................................0.02-0.052 mm (0.0008-0.0021 in.) Crankshaft Main Bearing Clearance Service..................................................................................................................0.02-0.065 mm (0.0008-0.0025 in.) Crankshaft Main Journal Diameter Production............................................................................................................64.992-65.008 mm (2.558-2.559 in.) Crankshaft Main Journal Diameter - Service............................................................ .............................................................................64.992 mm (2.558 in.) Crankshaft Main Journal Out-of-Round Production.......................................................................................................................0.003 mm (0.000118 in.) Crankshaft Main Journal Out-of-Round Service.................................................................................................................................0.008 mm (0.0003 in.) Crankshaft Main Journal Taper - Production..................................................................... .....................................................................0.01 mm (0.0004 in.) Crankshaft Main Journal Taper Service..............................................................................................................................................0. 02 mm (0.00078 in.) Crankshaft Rear Flange Runout.......................................................................... .......................................................................................0.05 mm (0.002 in.) Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 in) Below Tooth Diameter....................................................... ....................................................................................................................................0.7 mm (0.028 in.) Crankshaft Thrust Surface - Production......................................................................................... ...................................26.14-26.22 mm (1.029-1.0315 in.) Crankshaft Thrust Surface - Service......... .............................................................................................................................................26.22 mm (1.0315 in.) Crankshaft Thrust Surface Runout.................................................................................... ......................................................................0.025 mm (0.001 in.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Engine Block Heater: Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2800 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2801 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2802 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2803 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Engine Block Heater: All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2809 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2810 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2811 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2812 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 2818 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 2819 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 2820 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 2826 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 2827 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 2828 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement Engine Block Heater: Service and Repair Coolant Heater Cord Replacement Coolant Heater Cord Replacement (LY6) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the front 2 oil pan skid plate bolts, loosen the 2 rear bolts and remove the skid plate, if equipped. 3. Disconnect the coolant heater cord electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement > Page 2831 4. Remove the coolant heater cord clip (1) from the front brake front pipes. 5. Remove the coolant heater cord clip retainer (2) from the frame. 6. Lower the vehicle. 7. Remove the coolant heater cord bolt (3) from the frame. 8. Remove the coolant heater cord from the vehicle. Installation Procedure 1. Install the coolant heater cord to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Position the coolant heater cord clip to the frame and install the coolant heater cord bolt (3). Tighten the bolt to 8 Nm (71 lb in). 3. Raise the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement > Page 2832 4. Install the coolant heater cord clip retainer (2) to the frame. 5. Install the coolant heater cord clip (1) to the front brake front pipes. 6. Connect the coolant heater cord electrical connector. 7. Position the oil pan skid plate and install the 2 front bolts and tighten the 2 rear bolts, if equipped. Tighten the bolts to 20 Nm (15 lb ft). 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement > Page 2833 Engine Block Heater: Service and Repair Coolant Heater Cord Replacement (L76/L92) Coolant Heater Cord Replacement (L76/L92) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the oil pan skid plate bolts and plate, if equipped. 3. Disconnect the coolant heater cord electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement > Page 2834 4. Remove the coolant heater cord clip (3) from the engine harness channel. 5. Remove the coolant heater cord clip (1) from the power steering gear outlet hose. 6. Lower the vehicle. 7. Remove the coolant heater cord bolt (2) from the frame. 8. Remove the coolant heater cord from the vehicle. Installation Procedure 1. Install the coolant heater cord to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Position the coolant heater cord clip to the frame and install the coolant heater cord bolt (2). Tighten the bolt to 8 Nm (71 lb in). 3. Raise the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement > Page 2835 4. Install the coolant heater cord clip (1) to the power steering gear outlet hose. 5. Install the coolant heater cord clip (3) to the engine harness channel. 6. Connect the coolant heater cord electrical connector. 7. Position and install the oil pan skid plate and bolts, if equipped. Tighten the bolts to 20 Nm (15 lb ft). 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Balancer Bolt Step 1.......................................................................................................... ...............................................................................................150 Nm (110 lb ft.) Step 2..................... .............................................................................................................................................................. ......................Loosen 360 degrees Step 3........................................................................................... ..................................................................................................................80 Nm (59 lb ft.) Final Step. .............................................................................................................................................................. ................................................125 degrees Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2839 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement Special Tools * J 41478 Crankshaft Front Oil Seal Installer * J 41665 Crankshaft Balancer and Sprocket Installer * J 41816-A Crankshaft Balancer Remover * J 41816-2 Crankshaft End Protector * J 42386-A Flywheel Holding Tool * J 45059 Angle Meter Removal Procedure 1. Remove the air conditioning (A/C) drive belt. Refer to Air Conditioning Compressor Belt Replacement (V8) (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Air Conditioning Compressor Belt Replacement (V8)). 2. Remove the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement (Non-HP2) (See: Cooling System/Radiator Cooling Fan/Service and Repair). 3. Remove the starter motor. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair )Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Ensure that the teeth of the J 42386-A mesh with the teeth of the engine flywheel. 4. Install the J 42386-A (1) and bolts. Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation. Tighten the J 42386-A bolts to 50 Nm (37 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2840 5. Remove the crankshaft balancer bolt (139). Do not discard the crankshaft balancer bolt at this time. The old balancer bolt will be used during the balancer installation procedure. 6. Install the J 41816 (1) and J 41816-2 (2) to the crankshaft balancer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2841 Note: The crankshaft balancer is balanced as an individual component. It is not necessary to mark the balancer prior to removal. 7. Use the J 41816 and the J 41816-2 to remove the crankshaft balancer (138). 8. Remove the J 41816 and the J 41816-2 from the crankshaft balancer. Installation Procedure Note: * The crankshaft balancer installation and bolt tightening involves a four stage tightening process. The first pass ensures that the balancer is installed completely onto the crankshaft. The second, third, and fourth passes tighten the NEW bolt to the proper torque. * The used crankshaft balancer bolt will be used ONLY during the first pass of the balancer installation procedure. Install a NEW bolt and tighten as described in the second, third and fourth passes of the balancer bolt tightening procedure. Note: The balancer should be positioned onto the end of the crankshaft as straight as possible prior to tool installation. 1. Position the crankshaft balancer (138) onto the end of the crankshaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2842 2. Install the J 41665 and the threaded rod from the J 41478 to crankshaft balancer and install the balancer. 1. Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into the front of the balancer. 2. Use a wrench and hold the hex end of the threaded rod. 3. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft. 4. Remove the tool and reverse the installation tool. Position the larger end of the installer against the front of the balancer. 5. Use a wrench and hold the hex end of the threaded rod. 6. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft. 7. Remove the J 41665 and the threaded rod. 3. Install the USED crankshaft balancer bolt (139). Tighten the USED bolt to 330 Nm (240 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2843 4. Remove the USED crankshaft balancer bolt. Note: The nose of the crankshaft should be recessed 2.4-4.48 mm (0.094-0.176 in) into the balancer bore. 5. Measure for a correctly installed balancer. If the balancer is not installed to the proper dimension, install the J 41665 and repeat the installation procedure. 6. Install the NEW crankshaft balancer bolt (139). 1. Tighten the bolt a first pass to 50 Nm (37 lb ft). 2. Tighten the bolt a final pass to 140 degrees using J 45059 . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2844 7. Remove the J 42386-A (1) and bolts. 8. Install the starter motor. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 9. Install the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement (Non-HP2) (See: Cooling System/Radiator Cooling Fan/Service and Repair). 10. Install the A/C drive belt. Refer to Air Conditioning Compressor Belt Replacement (V8) (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Air Conditioning Compressor Belt Replacement (V8)). 11. Perform the crankshaft position (CKP) system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Powertrain Management/Computers and Control Systems/Crankshaft Position Sensor/Testing and Inspection). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > 6.0L RPO L96 VIN G Piston: Specifications 6.0L RPO L96 VIN G Pistons and Pins Pin - Piston Pin Clearance-to-Piston Pin Bore - Production..................................... ..................................................................................................................................0.002-0.01 mm (0.00008-0.0004 in.) Pin - Piston Pin Clearance-to-Piston Pin Bore - Service..................................... .....................................................................................................................................0.002-0.015 mm (0.00008-0.0006 in.) Pin - Piston Pin Diameter............................................................................. ...............................................................23.952-23.955 mm (0.9430-0.9431 in.) Pin - Piston Pin Fit in Connecting Rod Bore - Production................................................................................................... ..................................................................0.007-0.02 mm (0.00027-0.00078 in.) Pin - Piston Pin Fit in Connecting Rod Bore - Service........................................................................................................ ................................................................0.007-0.022 mm (0.00027-0.00086 in.) Piston - Piston Diameter - Measured Over Skirt Coating............................................................................................. ....................................101.615-101.649 mm (4.0006-4.0019 in.) Piston - Piston-to-Bore Clearance - Production...............................................................................................-0.031 to +0.021 mm (-0.0012 to +0.0008 in.) Piston - Piston-to-Bore Clearance - Service Limit with Skirt Coating Worn Off......................................................................................................................................................... ........0.071 mm (0.0028 in.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > 6.0L RPO L96 VIN G > Page 2849 Piston: Specifications 6.0L LY6 VIN K Pistons and Pins Pin - Piston Pin Clearance-to-Piston Pin Bore - Production..................................... ..................................................................................................................................0.002-0.01 mm (0.00008-0.0004 in.) Pin - Piston Pin Clearance-to-Piston Pin Bore - Service..................................... .....................................................................................................................................0.002-0.015 mm (0.00008-0.0006 in.) Pin - Piston Pin Diameter............................................................................. ...............................................................23.952-23.955 mm (0.9430-0.9431 in.) Pin - Piston Pin Fit in Connecting Rod Bore - Production................................................................................................... ..................................................................0.007-0.02 mm (0.00027-0.00078 in.) Pin - Piston Pin Fit in Connecting Rod Bore - Service........................................................................................................ ................................................................0.007-0.022 mm (0.00027-0.00086 in.) Piston - Piston Diameter - Measured Over Skirt Coating............................................................................................. .......................................................................101.615-101.649 mm (4.0006-4.0019 in.) Piston Piston-to-Bore Clearance Production...............................................................................................-0.031 to +0.021 mm (-0.0012 to +0.0008 in.) Piston - Piston-to-Bore Clearance - Service Limit with Skirt Coating Worn Off......................................................................................................................................................... ......................................0.071 mm (0.0028 in.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > 6.0L RPO L96 VIN G Piston Ring: Specifications 6.0L RPO L96 VIN G Piston Rings Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Producti on.......................................................................................................................................................... .................0.20-0.41 mm (0.0079-0.0161 in.) Piston Ring End Gap - First Compression Ring Measured in Cylinder Bore - Service.................................................................................................... ............................................................................0.20-0.46 mm (0.0079-0.0181 in.) Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production....................................... ....................................................................................................................................0.37-0.69 mm (0.0146-0.0272 in.) Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service............................................................................................................................................... .................................0.37-0.75 mm (0.0146-0.0295 in.) Piston Ring End Gap - Oil Control Ring Measured in Cylinder Bore - Production............................................................................................... ............................................................................0.22-0.79 mm (0.0086-0.0311 in.) Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Service............................................................. ...................................................................................................................0.22-0.84 mm (0.0086-0.0331 in.) Piston Ring-to-Groove Clearance - First Compression Ring - Production............ ............................................................................................................................................................. 0.04-0.083 mm (0.0016-0.0033 in.) Piston Ring-to-Groove Clearance - First Compression Ring - Se rvice...................................................................................................................................................... ........................0.04-0.083 mm (0.0016-0.0033 in.) Piston Ring-to-Groove Clearance - Second Compression Ring - Production............................................................................................................ ...........................................................0.035-0.078 mm (0.0014-0.0031 in.) Piston Ring-to-Groove Clearance - Second Compression Ring - Service................................................................................ ............................................................................................0.035-0.078 mm (0.0014-0.0031 in.) Piston Ring-to-Groove Clearance - Oil Control Ring - Production........................................................ ...............................................................................................................0.013-0.201 mm (0.0005-0.0079 in.) Piston Ring-to-Groove Clearance - Oil Control Ring - Service............................. ...............................................................................................................................................0.013-0. 201 mm (0.0005-0.0079 in.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > 6.0L RPO L96 VIN G > Page 2854 Piston Ring: Specifications 6.0L LY6 VIN K Piston Rings Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Producti on.......................................................................................................................................................... .................0.20-0.41 mm (0.0079-0.0161 in.) Piston Ring End Gap - First Compression Ring Measured in Cylinder Bore - Service.................................................................................................... ............................................................................0.20-0.46 mm (0.0079-0.0181 in.) Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production....................................... ....................................................................................................................................0.37-0.69 mm (0.0146-0.0272 in.) Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service............................................................................................................................................... .................................0.37-0.75 mm (0.0146-0.0295 in.) Piston Ring End Gap - Oil Control Ring Measured in Cylinder Bore - Production............................................................................................... ............................................................................0.22-0.79 mm (0.0086-0.0311 in.) Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Service............................................................. ...................................................................................................................0.22-0.84 mm (0.0086-0.0331 in.) Piston Ring-to-Groove Clearance - First Compression Ring - Production............ ............................................................................................................................................................. 0.04-0.083 mm (0.0016-0.0033 in.) Piston Ring-to-Groove Clearance - First Compression Ring - Se rvice...................................................................................................................................................... ........................0.04-0.083 mm (0.0016-0.0033 in.) Piston Ring-to-Groove Clearance - Second Compression Ring - Production............................................................................................................ ...........................................................0.035-0.078 mm (0.0014-0.0031 in.) Piston Ring-to-Groove Clearance - Second Compression Ring - Service................................................................................ ............................................................................................0.035-0.078 mm (0.0014-0.0031 in.) Piston Ring-to-Groove Clearance - Oil Control Ring - Production........................................................ ...............................................................................................................0.013-0.201 mm (0.0005-0.0079 in.) Piston Ring-to-Groove Clearance - Oil Control Ring - Service............................. ...............................................................................................................................................0.013-0. 201 mm (0.0005-0.0079 in.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief (CH-48027) Special Tools CH-48027 - Digital Pressure Gauge Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Page 2859 * The fuel pipe connections * The hose connections * The areas surrounding the connections Note: If relieving the fuel pressure for the fuel pressure gauge installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side). Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. 2. Remove the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). Note: Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 3. Remove the rocker arm bolts. 4. Remove the rocker arms. 5. Remove the rocker arm pivot support. 6. Remove the pushrods. 7. Clean and inspect the rocker arms and pushrods, if required. Refer to Valve Rocker Arm and Push Rod Cleaning and Inspection (See: Service Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 2863 and Repair/Overhaul/29. Valve Rocker Arm and Push Rod Cleaning and Inspection). Installation Procedure Note: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. 1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the rocker arm. 3. Install the rocker arm pivot support. Note: Make sure that the pushrods seat properly to the valve lifter sockets. 4. Install the pushrods. Note: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. 5. Install the rocker arms and bolts. Note: The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinders 2, 4, 6 and 8 are the right bank. 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, the number one cylinder rocker arms will be off lobe lift. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 2864 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. With the engine in the number one firing position, tighten the following rocker arm bolts: * Tighten cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 Nm (22 lb ft). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts: * Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 lb ft). 10. Install the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 11. Install the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Left Side Valve Rocker Arm Cover Replacement - Left Side Removal Procedure 1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair). 2. Remove the connector position assurance (CPA) retainer (2). 3. Disconnect the engine harness electrical connector (1) from the ignition coil wire harness. 4. Remove the engine harness clip (4) from the ignition coil bracket stud. 5. Reposition the engine harness, as necessary. 6. Remove the spark plug wires (724) from the ignition coils. * Twist each plug wire 1/2 turn. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 2869 * Pull only on the boot in order to remove the wire from the ignition coil. 7. Remove the ignition coil bracket studs (720). 8. Remove the ignition coil bracket (719). 9. Remove the positive crankcase ventilation (PCV) hose. 10. Loosen the valve rocker arm cover bolts. 11. Remove the valve rocker arm cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 2870 12. Remove and discard the old gasket (1). Installation Procedure Note: * All gasket surfaces should be free of oil an/or other foreign material during assembly. * DO NOT reuse the valve rocker arm cover gasket. * If the PCV valve grommet has been removed from the rocker cover, install a NEW grommet during assembly. 1. Install a NEW rocker cover gasket (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 2871 2. Install the valve rocker arm cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the rocker arm cover bolts. Tighten the bolts to 12 Nm (106 lb in). 4. Install the PCV hose. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 2872 5. Apply threadlock to the threads of the ignition coil bracket studs. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). 6. Position the ignition coil bracket (719) onto the rocker cover. 7. Install the ignition coil bracket studs (720). Tighten the studs to 12 Nm (106 lb in). 8. Install the spark plug wires (724) to the ignition coils. 9. Position the engine harness, as necessary. 10. Install the engine harness clip (4) to the ignition coil bracket stud. 11. Connect the engine harness electrical connector (1) to the ignition coil wire harness. 12. Install the CPA retainer (2). 13. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 2873 Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Right Side Valve Rocker Arm Cover Replacement - Right Side Removal Procedure 1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair). 2. Remove the connector position assurance (CPA) retainer (2). 3. Disconnect the engine harness electrical connector (1) from the ignition coil wire harness. 4. Remove the engine wiring harness (electronic throttle control branch) clip (6) from the ignition coil bracket stud. 5. Reposition the engine wiring harness (electronic throttle control branch) as necessary. 6. Remove the generator battery cable clip (1) from the ignition coil bracket stud. 7. Reposition the generator battery cable as necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 2874 8. Remove the heater inlet hose (2) from the heater hose bracket (3). 9. Remove the surge tank outlet hose (2) from the heater hose bracket (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 2875 10. Remove the heater hose bracket nut and bracket 11. Remove the spark plug wires (724) from the ignition coils. * Twist each plug wire 1/2 turn. * Pull only on the boot in order to remove the wire from the ignition coil. 12. Remove the ignition coil bracket studs (720). 13. Remove the ignition coil bracket (719). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 2876 14. Remove the positive crankcase ventilation (PCV) tube (1) from the valve rocker cover (2). 15. Loosen the valve rocker arm cover bolts. 16. Remove the valve rocker arm cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 2877 17. Remove and discard the old gasket (1). 18. Remove the oil fill cap (424) from the oil fill tube (423), if necessary. 19. Remove and discard the oil fill tube, if necessary. Installation Procedure Note: * All gasket surfaces should be free of oil or other foreign material during assembly. * DO NOT reuse the valve rocker arm cover gasket. * If the oil fill tube has been removed from the rocker arm cover, install a NEW fill tube during assembly. 1. Lubricate the O-ring seal (422) of the NEW oil fill tube with clean engine oil. 2. Insert the NEW oil fill tube (423) into the rocker arm cover. Rotate the tube clockwise until locked in the proper position. 3. Install the oil fill cap (424) into the tube. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 2878 Rotate the cap clockwise until locked in the proper position. 4. Install a NEW rocker cover gasket (1) into the valve rocker arm cover lip. 5. Install the valve rocker arm cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Tighten the rocker arm cover bolts. Tighten the bolts to 12 Nm (106 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 2879 7. Install the PCV tube (1) to the valve rocker cover (2). 8. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the ignition coil bracket studs. 9. Position the ignition coil bracket (719) onto the rocker cover. 10. Install the ignition coil bracket studs (720). Tighten the studs to 12 Nm (106 lb in). 11. Install the spark plug wires (724) to the ignition coils. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 2880 12. Install the heater hose bracket and nut. Tighten the nut to 9 Nm (80 lb in). 13. Install the surge tank outlet hose (2) to the heater hose bracket (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 2881 14. Install the heater inlet hose (2) to the heater hose bracket (3). 15. Position the generator battery cable as necessary. 16. Install the generator battery cable clip (1) to the ignition coil bracket stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 2882 17. Position the engine wiring harness (electronic throttle control branch) as necessary. 18. Install the engine wiring harness (electronic throttle control branch) clip (6) to the ignition coil bracket stud. 19. Connect the engine harness electrical connector (1) to the ignition coil wire harness. 20. Install the CPA retainer (2). 21. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service Precautions Valve Spring: Service Precautions Valve Springs Can Be Tightly Compressed Warning Warning Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service Precautions > Page 2886 Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Special Tools * J 22794 Spark Plug Port Adapter * J 38606 Valve Spring Compressor Removal Procedure 1. Remove the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See: Rocker Arm Assembly/Service and Repair). 2. Disconnect the spark plug wire at the spark plug. * Twist each plug wire boot 1/2 turn. * Pull only on the boot in order to remove the wire from the spark plug. Note: Remove the spark plugs from the cylinder head with the engine at room temperature. 3. Loosen the spark plug 1 or 2 turns. 4. Brush or air blast away any dirt or debris from around the spark plug. 5. Remove the spark plug. 6. Install the J 22794 into the spark plug hole. 7. Attach an air hose to the J 22794 . 8. Apply compressed air to the J 22794 in order to hold the valves in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service Precautions > Page 2887 9. Use the J 38606 in order to compress the valve spring. 10. Remove the valve stem keys (225). 11. Carefully release the valve spring tension. 12. Remove the J 38606 . 13. Remove the valve spring cap (224). 14. Remove the valve spring (223). 15. Remove the valve stem oil seal (222). 16. Remove the valve (228). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service Precautions > Page 2888 1. Clean the cylinder head valve spring seat area. 2. Lubricate the valve guide and valve stem oil seal with clean engine oil. 3. Install the valves (228) into the proper port. 4. Install the valve stem oil seal (222). 5. Install the valve spring (223). 6. Install the valve spring cap (224). 7. Compress the valve spring using the J 38606 . 8. Install the valve keys. * Use grease in order to hold the valve keys in place. * Make sure the keys seat properly in the groove of the valve stem. * Carefully release the valve spring pressure, making sure the valve keys stay in place. * Remove the J 38606 . * Tap the end of the valve stem with a plastic faced hammer to seat the keys, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service Precautions > Page 2889 9. Remove the J 22794 from the spark plug port. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 10. Hand start the spark plug. Tighten the spark plug to 15 Nm (11 lb ft). 11. Install the spark plug wires at the ignition coil. 12. Install the spark plug wire to the spark plug. 13. Inspect the wires for proper installation: * Push sideways on each boot in order to check for proper installation. * Reinstall any loose boot. 14. Install the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See: Rocker Arm Assembly/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2895 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2896 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2897 Drive Belt: Diagrams Drive Belt Replacement - Accessory Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2898 Drive Belt: Service Precautions Belt Dressing Caution Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2899 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: * The drive belt * The drive belt tensioner * The drive belt idler pulley * The crankshaft balancer pulley * The accessory drive component mounting brackets * The accessory drive components - The power steering pump - The generator - The A/C compressor - The engine cooling fan - The water pump, if belt driven The drive belt system may use 2 belts. The drive belt (1) is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of different types of rubbers - chloroprene or EPDM - and have different layers or plies containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system has an idler pulley, which is used to add wrap to the adjacent pulleys. A/C Compressor Drive Belt Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2900 The outward appearance of the belt (1) is similar to the current design serpentine belt. The reinforcing cord provides its unique qualities. The belt cord is made of a polyamid material. The polyamid cord is more elastic than the more traditional aramid or polyester cord designs. A tensioner is not needed. Polyamid cord, when combined with a more elastic backing compound, ensures the belt is able to maintain the specified tension within the specified range of usage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt Chirping, Squeal, and Whine Diagnosis Diagnostic Aids * A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. * If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. * A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise. * The drive belts will not cause a whine noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 2903 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 2904 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 2905 Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis Drive Belt Rumbling and Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 2906 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 2907 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 2908 Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis Drive Belt Falls Off and Excessive Wear Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspection of the fasteners can eliminate the possibility that a wrong bolt, nut , spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 2909 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Air Conditioning Compressor Belt Replacement (V8) Drive Belt: Service and Repair Air Conditioning Compressor Belt Replacement (V8) Air Conditioning Compressor Belt Replacement (V8) Removal Procedure 1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt Replacement - Accessory). 2. Remove the skid plate. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Cut the belt (1) from air conditioning (A/C) and crankshaft pulleys. Installation Procedure Note: The OEM replacement stretchy belt is packaged with a disposable installation tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Air Conditioning Compressor Belt Replacement (V8) > Page 2912 1. Position the belt behind the rear face of the balancer (1) and off of the A/C pulley (2). 2. Install the belt installation tool (3) onto the balancer. 3. Slide the belt installation tool (1) upward, installing the belt (2) onto the belt installation tool. 4. Slide the belt installation tool downward, positioning the belt onto the A/C pulley, applying light tension to the belt. 5. Position the lower portion of the belt (1) with the ribbed area facing forward. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Air Conditioning Compressor Belt Replacement (V8) > Page 2913 6. Slowly rotate the crankshaft pulley (1) in a clockwise direction while using finger pressure to pull the belt (2) forward. Ensure that the ribbed area of the belt remains facing forward and the belt aligns properly to the A/C pulley. 7. Inspect the drive belt (1) for proper installation and alignment. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Air Conditioning Compressor Belt Replacement (V8) > Page 2914 8. Rotate the balancer (1) and additional 360 degrees to ensure proper belt installation. 9. Install the skid plate. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 10. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt Replacement - Accessory). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Air Conditioning Compressor Belt Replacement (V8) > Page 2915 Drive Belt: Service and Repair Drive Belt Replacement - Accessory Drive Belt Replacement - Accessory Removal Procedure 1. Open the hood. 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 3. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 4. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt. 5. Remove the drive belt (1) from the pulleys and the drive belt tensioner. 6. Slowly release the tension on the drive belt tensioner. 7. Remove the breaker bar and socket and from the drive belt tensioner bolt. 8. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure 1. Route the drive belt (1) around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. 7. Inspect the drive belt for proper installation and alignment. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 9. Start the vehicle and inspect the drive belt for proper operation. 10. Close the hood. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 2919 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement - Accessory Removal Procedure 1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt/Service and Repair/Drive Belt Replacement Accessory). 2. Remove the drive belt tensioner bolts. 3. Remove the drive belt tensioner. Installation Procedure 1. Position the drive belt tensioner to the water pump. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 2920 2. Install and tighten the drive belt tensioner bolts. Tighten the bolts to 50 Nm (37 lb ft). 3. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt/Service and Repair/Drive Belt Replacement Accessory). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection Engine Mount: Testing and Inspection Engine Mount Inspection Caution: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. Caution: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit. 1. Measure the engine movement at the engine mount in order to check for damage to the rubber portions of the mount. 1. Apply the park brake. 2. Start the engine. 3. Firmly apply and hold the primary brakes. 4. Have an assistant stand to the side of the vehicle in order to observe for engine movement. 5. Slightly load the engine shifting from drive to reverse a few times. 6. If the engine moves more than 24 mm (0.945 in) from the at rest position, in either direction, check for loose engine mount bolts. 2. If the engine mount bolt torque is within specifications, check the condition of the engine mount. 3. Replace the engine mount if any of the following conditions exist: * Heat check cracks cover the rubber cushion surface. * The rubber cushion is separated from the metal plate of the mount. * There is a split through the rubber cushion. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection > Page 2924 Engine Mount: Service and Repair Engine Mount Bracket Replacement - Left Side Removal Procedure 1. Remove the engine mount. Refer to Engine Mount Replacement - Left Side (1500 LY2) (See: )Engine Mount Replacement - Left Side (1500 Except RPOs LY6, LY2) (See: )Engine Mount Replacement - Left Side (2500 LY6) (See: ). 2. Remove the engine mount bracket bolts. 3. Remove the engine mount bracket. Installation Procedure 1. Position the engine mount bracket onto the frame. 2. Perform the following steps prior to installing the engine mount bracket bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection > Page 2925 * Remove all traces of the original adhesive patch. * Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. * Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the engine mount bracket bolts. Tighten the bolts to 65 Nm (48 lb ft). 4. Install the engine mount. Refer to Engine Mount Replacement - Left Side (1500 LY2) (See: )Engine Mount Replacement - Left Side (1500 Except RPOs LY6, LY2) (See: )Engine Mount Replacement - Left Side (2500 LY6) (See: ). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement Removal Procedure 1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt/Service and Repair/Drive Belt Replacement - Accessory). 2. Loosen the drive belt idler pulley bolt and remove the idler pulley. Installation Procedure 1. Position the drive belt idler pulley to the generator bracket and tighten the idler pulley bolt finger tight. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the drive belt idler pulley bolt. Tighten the bolt to 50 Nm (37 lb ft). 3. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt/Service and Repair/Drive Belt Replacement Accessory). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum - Hot .......................................................................................................................................................41 kPa at 1,000 engine RPM 6 psig at 1,000 engine RPM ...................................................................................................................................................124 kPa at 2,000 engine RPM 18 psig at 2,000 engine RPM ...................................................................................................................................................165 kPa at 4,000 engine RPM 24 psig at 4,000 engine RPM Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 2933 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Tools Required * EN-47971 Oil Pressure Gauge Adapter * J 21867 Pressure Gauge 1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gauge or light. 4. Listen for a noisy valve train or a knocking noise. 5. Inspect for the following conditions: * Oil diluted by water or glycol antifreeze Refer to Coolant in Engine Oil (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Coolant in Engine Oil). * Foamy oil, which may be caused by a cut or damaged oil pump screen O-ring seal 6. Remove the oil filter and install the EN-47971 (1). 7. Install the J 21867 (2), or equivalent to the EN-47971 (1). 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to Engine Mechanical Specifications (RPO L20 VIN A) (See: Specifications/Service Limits & General Specifications )Engine Mechanical Specifications (RPO L96 VIN G) (See: Specifications/Service Limits & General Specifications/Engine Mechanical Specifications/6.0L RPO L96 VIN G)Engine Mechanical Specifications (RPO L9H) (See: Specifications/Service Limits & General Specifications)Engine Mechanical Specifications (RPO LC9 VIN 3) ()Engine Mechanical Specifications (RPO LMG VIN 0) ()Engine Mechanical Specifications (RPO LY6 VIN K) (See: Specifications/Service Limits & General Specifications/Engine Mechanical Specifications/6.0L RPO LY6 VIN K). 10. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the following conditions: * Improper operation of the active fuel management oil pressure relief valve Refer to Cylinder Deactivation (Active Fuel Management) Oil Pressure Relief Valve Diagnosis and Testing (See: Testing and Inspection/Component Tests and General Diagnostics). * Oil pump worn or dirty Refer to Oil Pump Cleaning and Inspection (See: Service and Repair/Overhaul/36. Oil Pump Cleaning and Inspection). * Oil pump-to-engine block bolts loose Refer to Oil Pump, Screen and Crankshaft Oil Deflector Installation (See: Service and Repair/Overhaul/95. Oil Pump, Screen and Crankshaft Oil Deflector Installation). * Oil pump screen loose, plugged, or damaged * Oil pump screen O-ring seal missing or damaged * Malfunctioning oil pump pressure relief valve Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 2934 * Excessive bearing clearance * Cracked, porous, or restricted oil galleries * Oil gallery plugs missing or incorrectly installed Refer to Engine Block Plug Installation (See: Service and Repair/Overhaul/45. Engine Block Plug Installation). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator Tube Replacement Removal Procedure 1. Remove the oil level indicator (418). 2. Remove the oil level indicator tube bolt (419). 3. Remove the oil level indicator tube (420) from the engine block. Note: The O-ring seal may be reused if not cut or damaged. 4. Inspect the O-ring seal for cuts or damage. 5. Remove the O-ring seal (421) from the tube, if required. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Page 2938 1. Lubricate the O-ring seal (421) with clean engine oil. 2. Install a NEW O-ring seal onto the oil level indicator tube, if required. 3. Install the oil level indicator tube (420) between the exhaust manifold and engine block. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Insert the oil level indicator tube into the block. The tube must be installed with the collar flush to the block. 6. Lower the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the oil level indicator tube bolt (419). Tighten the bolt to 25 Nm (18 lb ft). 8. Install the oil level indicator (418). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up Engine Oil: Customer Interest Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 2947 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: All Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2953 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 11-00-90-001 > Mar > 11 > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2954 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up Engine Oil: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 2959 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Radio/Stereo Noise Filter: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 2965 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 2971 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ............................................... 6.0 quarts (5.7 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2974 Engine Oil: Fluid Type Specifications ENGINE OIL TYPE Look for three things: 1. Your vehicle's engine requires oil meeting GM Standard GM6094M. 2. Oils meeting these requirements should also have the starburst symbol on the container. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). You should look for this information on the oil container 3. All temperatures above -20°F (-29°C) SAE 5W-30 is best for your vehicle. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 10W-40, SAE 20W-50, or any other viscosity grade not recommended. NOTICE: Use only engine oil identified as meeting GM Standard GM6094M and showing the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by your warranty. GM Goodwrench oil meets all the requirements for your vehicle. If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will provide easier cold starting and better protection for your engine at extremely low temperatures. ENGINE OIL ADDITIVES / ENGINE OIL FLUSHES Do not add anything to your oil. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all you will need for good performance and engine protection. Engine oil system flushes are not recommended and could cause engine damage not covered by the vehicle warranty. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2975 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to drain completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and inspect the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2976 10. Position the drain pan under the oil filter (437). 11. Remove the oil filter. 12. Ensure that the oil filter gasket is still on the old filter if not, remove the oil filter gasket from the oil pan. Installation Procedure 1. Apply clean engine oil to the NEW oil filter seal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW oil filter (437) and tighten to 30 Nm (22 lb ft). 3. Tighten the oil pan drain plug (430) to 25 Nm (18 lb ft). 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities (See: Maintenance/Specifications) and Fluid and Lubricant Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2977 Recommendations (USA and Canada) (See: Maintenance). 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Control Valve > Component Information > Service and Repair Engine Oil Control Valve: Service and Repair Oil Pressure Relief Valve Replacement Removal Procedure 1. Remove the oil pan. Refer to Oil Pan Replacement (4WD) (See: Oil Pan/Service and Repair/Oil Pan Replacement)Oil Pan Replacement (2WD) (See: Oil Pan/Service and Repair/Oil Pan Replacement). 2. Place the oil pan on a clean work surface. 3. Remove the oil pressure relief valve (455) and washer. Installation Procedure 1. Inspect the NEW oil pressure relief valve for proper operation. Lightly depress the ball (2). The valve spring (1) should seat the ball to the proper closed position. 2. Install the NEW oil pressure relief valve (455) and washer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Control Valve > Component Information > Service and Repair > Page 2981 3. Install the oil pan. Refer to Oil Pan Replacement (4WD) (See: Oil Pan/Service and Repair/Oil Pan Replacement)Oil Pan Replacement (2WD) ( See: Oil Pan/Service and Repair/Oil Pan Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Technical Service Bulletins > Customer Interest for Oil Cooler: > 08-06-02-003A > Oct > 10 > Engine - Oil Leak At Oil Cooler Hose/Pipe Assembly Oil Cooler: Customer Interest Engine - Oil Leak At Oil Cooler Hose/Pipe Assembly TECHNICAL Bulletin No.: 08-06-02-003A Date: October 27, 2010 Subject: Engine Oil Leak at Engine Oil Cooler Hose/Pipe Adapter to Engine Connection (Diagnose and Repair as Outlined) Models: 2007-2011 Chevrolet Silverado, Suburban, Tahoe 2008-2011 Chevrolet Express 2007-2011 GMC Sierra, Yukon, Yukon XL 2008-2011 GMC Savana Equipped with 4.8L, 5.3L, 6.0L or 6.2L V8 Engine (VIN Code C, M, L, J, 4, 0, 3, 5, K, Y, 8 or 2 - RPO LY2, LH6, LY5, LMF, LMG, LC9, LFA, LY6, L76, L92 or L9H) and Engine Oil Cooling System RPO KC4 Supercede: This bulletin is being revised to clarify the Subject text, add model years, Cause, Correction, graphics and part number information. Please discard Corporate Bulletin Number 08-06-02-003 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine oil leak. Upon further investigation, the technician may find engine oil leaking from the engine oil cooler hose/pipe adapter at the point where it connects to the engine. Cause This condition may be caused by any of the following: - A damaged engine oil cooler hose/pipe adapter gasket, due to a temporary steel sealing device not being removed when the engine oil cooler hose/pipe adapter was first connected to the engine. - Previous oil leak servicing of the engine oil cooler hose/pipe adapter gasket that involved failing to remove the temporary steel sealing device. - Casting porosity at the engine oil cooler hose/pipe adapter bolt holes of the engine. - The engine oil cooler hose/pipe adapter bolts are not torqued to the proper specification. Correction 1. Perform the oil leak diagnosis procedure. Refer to Oil Leak Diagnosis in SI. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 3. The temporary steel sealing device (1) is shown separately from the adapter gasket (2). The temporary steel sealing device SHOULD NOT be installed on the engine or the engine oil cooler hose/pipe adapter. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Technical Service Bulletins > Customer Interest for Oil Cooler: > 08-06-02-003A > Oct > 10 > Engine - Oil Leak At Oil Cooler Hose/Pipe Assembly > Page 2990 Inspect closely for the temporary steel sealing device (1) being positioned tightly to the gasket (2) as shown. Only a small corner (1) of the temporary steel sealing device may be observable, depending on orientation. Perform a visual inspection in order to verify that the oil leak is coming from the engine oil cooler hose/pipe adapter area or the gasket where it connects to the engine. ‹› If the leak is coming from the engine oil cooler hose/pipe adapter area, the bolts or the gasket where it connects to the engine, proceed to Step 4. ‹› If the leak is not coming from the engine oil cooler hose/pipe adapter area, the bolts or the gasket where it connects to the engine, refer to Oil Leak Diagnosis in SI. 4. To gain clearance, loosen or remove the engine oil cooler hose/pipe retaining bracket bolt (1). 5. Remove the engine oil cooler hose/pipe adapter bolts (2). 6. Remove and DISCARD both the temporary steel sealing device if present and the gasket. 7. Clean the mating surfaces of the engine oil cooler hose/pipe adapter and the engine. 8. Clean both bolt holes with brake cleaner and dry using regulated compressed air. 9. Clean both bolt threads and apply Pipe Sealant P/N 12346004 (Canada P/N 10953480) or equivalent (Loctite(R) 565) to the bolt threads. Verify that the sealant is applied 360 degrees around the bolt and extends from the tip of the bolt and covers at least 15 mm (0.59 in) of threads. 10. Install the engine oil cooler hose/pipe adapter with a NEW gasket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Technical Service Bulletins > Customer Interest for Oil Cooler: > 08-06-02-003A > Oct > 10 > Engine - Oil Leak At Oil Cooler Hose/Pipe Assembly > Page 2991 11. Install the engine oil cooler hose/pipe adapter bolts (2) and: Tighten Tighten the bolts to 12 Nm (106 lb in). 12. Install the engine oil cooler hose/pipe retaining bracket bolt (1) and: Tighten Tighten the bolt to 25 Nm (18 lb ft). 13. Verify the correct engine oil level. 14. Verify the repair. Refer to Oil Leak Diagnosis in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Technical Service Bulletins > Customer Interest for Oil Cooler: > 08-06-02-003A > Oct > 10 > Engine - Oil Leak At Oil Cooler Hose/Pipe Assembly > Page 2992 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Cooler: > 08-06-02-003A > Oct > 10 > Engine - Oil Leak At Oil Cooler Hose/Pipe Assembly Oil Cooler: All Technical Service Bulletins Engine - Oil Leak At Oil Cooler Hose/Pipe Assembly TECHNICAL Bulletin No.: 08-06-02-003A Date: October 27, 2010 Subject: Engine Oil Leak at Engine Oil Cooler Hose/Pipe Adapter to Engine Connection (Diagnose and Repair as Outlined) Models: 2007-2011 Chevrolet Silverado, Suburban, Tahoe 2008-2011 Chevrolet Express 2007-2011 GMC Sierra, Yukon, Yukon XL 2008-2011 GMC Savana Equipped with 4.8L, 5.3L, 6.0L or 6.2L V8 Engine (VIN Code C, M, L, J, 4, 0, 3, 5, K, Y, 8 or 2 - RPO LY2, LH6, LY5, LMF, LMG, LC9, LFA, LY6, L76, L92 or L9H) and Engine Oil Cooling System RPO KC4 Supercede: This bulletin is being revised to clarify the Subject text, add model years, Cause, Correction, graphics and part number information. Please discard Corporate Bulletin Number 08-06-02-003 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine oil leak. Upon further investigation, the technician may find engine oil leaking from the engine oil cooler hose/pipe adapter at the point where it connects to the engine. Cause This condition may be caused by any of the following: - A damaged engine oil cooler hose/pipe adapter gasket, due to a temporary steel sealing device not being removed when the engine oil cooler hose/pipe adapter was first connected to the engine. - Previous oil leak servicing of the engine oil cooler hose/pipe adapter gasket that involved failing to remove the temporary steel sealing device. - Casting porosity at the engine oil cooler hose/pipe adapter bolt holes of the engine. - The engine oil cooler hose/pipe adapter bolts are not torqued to the proper specification. Correction 1. Perform the oil leak diagnosis procedure. Refer to Oil Leak Diagnosis in SI. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 3. The temporary steel sealing device (1) is shown separately from the adapter gasket (2). The temporary steel sealing device SHOULD NOT be installed on the engine or the engine oil cooler hose/pipe adapter. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Cooler: > 08-06-02-003A > Oct > 10 > Engine - Oil Leak At Oil Cooler Hose/Pipe Assembly > Page 2998 Inspect closely for the temporary steel sealing device (1) being positioned tightly to the gasket (2) as shown. Only a small corner (1) of the temporary steel sealing device may be observable, depending on orientation. Perform a visual inspection in order to verify that the oil leak is coming from the engine oil cooler hose/pipe adapter area or the gasket where it connects to the engine. ‹› If the leak is coming from the engine oil cooler hose/pipe adapter area, the bolts or the gasket where it connects to the engine, proceed to Step 4. ‹› If the leak is not coming from the engine oil cooler hose/pipe adapter area, the bolts or the gasket where it connects to the engine, refer to Oil Leak Diagnosis in SI. 4. To gain clearance, loosen or remove the engine oil cooler hose/pipe retaining bracket bolt (1). 5. Remove the engine oil cooler hose/pipe adapter bolts (2). 6. Remove and DISCARD both the temporary steel sealing device if present and the gasket. 7. Clean the mating surfaces of the engine oil cooler hose/pipe adapter and the engine. 8. Clean both bolt holes with brake cleaner and dry using regulated compressed air. 9. Clean both bolt threads and apply Pipe Sealant P/N 12346004 (Canada P/N 10953480) or equivalent (Loctite(R) 565) to the bolt threads. Verify that the sealant is applied 360 degrees around the bolt and extends from the tip of the bolt and covers at least 15 mm (0.59 in) of threads. 10. Install the engine oil cooler hose/pipe adapter with a NEW gasket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Cooler: > 08-06-02-003A > Oct > 10 > Engine - Oil Leak At Oil Cooler Hose/Pipe Assembly > Page 2999 11. Install the engine oil cooler hose/pipe adapter bolts (2) and: Tighten Tighten the bolts to 12 Nm (106 lb in). 12. Install the engine oil cooler hose/pipe retaining bracket bolt (1) and: Tighten Tighten the bolt to 25 Nm (18 lb ft). 13. Verify the correct engine oil level. 14. Verify the repair. Refer to Oil Leak Diagnosis in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Cooler: > 08-06-02-003A > Oct > 10 > Engine - Oil Leak At Oil Cooler Hose/Pipe Assembly > Page 3000 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement Oil Cooler: Service and Repair Engine Oil Cooler Connector Replacement Engine Oil Cooler Connector Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 3003 Oil Cooler: Service and Repair Engine Oil Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Engine Oil Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Special Tools * DT-47731 1/2 in Line Quick Release Tool * J 28585 Universal Snap Ring Remover for the 5/8 in Line Removal Procedure 1. Remove the plastic caps from the quick connect fittings by pulling the caps back along the pipe before installation. 2. Install the DT-47731 onto the engine oil cooler (EOC) pipe, or use the J 28585 3. Slide the DT-47731 toward the EOC pipe fitting, or use the J 28585 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 3004 Note: Rotate the DT-47731 to engage the EOC pipe fitting's retainer slots. The DT-47731 should be nearly flush with the fitting. 4. Connect the DT-47731 onto the EOC pipe fitting. 5. Rotate the DT-47731 or use the J 28585 until the retainer clip (1) rises above the fitting retainer seat. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 3005 6. Pull back on the EOC pipe to disengage the pipe from the EOC pipe fitting. 7. Remove the DT-47731 or the J 28585 from the EOC pipe. Installation Procedure Note: Discard the EOC retaining clip and install a new retaining clip. 1. Install the EOC pipe into the EOC pipe fitting. A distinct snap should be heard or felt when assembling the EOC pipe to the fitting. 2. To ensure the cooler line is properly installed, give the cooler pipe a gentle pull. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 3006 Oil Cooler: Service and Repair Engine Oil Cooler Hose/Pipe Replacement Engine Oil Cooler Hose/Pipe Replacement Removal Procedure The optional oil cooler is either an integral part of the radiator or a separate unit placed in front of the radiator. The cooler lines and hoses are serviceable. 1. Disconnect the engine oil cooler quick connect fittings. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement (See: Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement). 2. If equipped with regular production option (RPO) L76 (6.0L) engine, perform the following. 1. Open the oil cooler hose clip located on the lower fan shroud. 2. Remove the oil cooler hoses from the clip. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 3007 4. If equipped with RPO LY6 (6.0L) engine, remove the oil cooler hoses from the clip. 5. Place a jack or utility stands at the rear of the vehicle. 6. If equipped, remove the engine protection shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 7. For both 1500 and 2500 series, support the front differential carrier with a suitable adjustable jack. 8. For 1500 series vehicles, remove the differential carrier right side nuts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 3008 9. Remove the differential carrier left side bolts. 10. Lower the differential carrier. 11. For 2500 series vehicles, remove the differential carrier right side nuts. 12. Remove the differential carrier upper mounting bolt and nut. 13. Remove the differential carrier lower mounting bolt and nut. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 3009 14. If equipped with RPO L76 (6.0L) engine, perform the following: 1. Lower the differential carrier. 2. Remove the oil cooler hose adapter bolts (2). 3. Remove the oil cooler hose assembly and gasket. Discard the gasket. 4. Inspect the fittings, connectors, and cooler hoses for damage or distortion. 15. If equipped with RPO LY6 (6.0L) engine, perform the following: 1. Remove the oil cooler hose bracket bolt. (1) 2. Remove the oil cooler hose adapter bolts. (2) 3. Remove the oil cooler hose assembly. Discard the gasket. 4. Inspect the fittings, connectors, and cooler hoses for damage or distortion. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 3010 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. If equipped with RPO LY6 (6.0L) engine, perform the following: 1. Install the oil cooler hose assembly and a NEW gasket. 2. Install the oil cooler hose adapter bolts (2). Tighten the bolts to 12 Nm (106 lb in). 3. Install the oil cooler hose bracket bolt. Tighten the bolt to 25 Nm (18 lb ft). 2. If equipped with a RPO L76 (6.0L) engine, perform the following. 1. Install the oil cooler hose assembly and a NEW gasket. 2. Install the oil cooler hose adapter bolts (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 3011 Tighten the bolts to 12 Nm (106 lb in). 3. Install the oil cooler hose bracket bolt (1). Tighten the bolt to 25 Nm (18 lb ft). 3. For 2500 series vehicles, raise the differential carrier into position. 4. Install the differential carrier left side upper bolt and nut until snug. 5. Install the differential carrier left side lower bolt and nut until snug. 6. Install the differential carrier right side nuts. Tighten the bolt to 100 Nm (74 lb ft). 7. For 1500 series vehicles, raise the differential carrier into position. 8. Install the differential carrier right side nuts. 9. Install the differential carrier left side bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 3012 Tighten the bolts/nuts to 100 Nm (74 lb ft). 10. If equipped, install the engine protection shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 11. Remove the jack or utility stand from the rear of the vehicle. 12. Lower the vehicle. Note: * Ensure the oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap onto the cooler line prior cooler line installation. * Do not use the plastic cap in order to install the cooler line into the fitting. 13. If equipped with RPO LY6 (6.0L) engine, install the oil cooler hoses to the clip. Note: * Ensure the oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 3013 plastic cap is damaged, obtain a new cap. Install the cap onto the cooler line prior cooler line installation. * Do not use the plastic cap in order to install the cooler line into the fitting. 14. If equipped with RPO L76 (6.0L) engine, perform the following: 1. Install the oil cooler hoses to the hose clip on the fan shroud. 2. Snap the oil cooler hose clip shut. 15. Install the oil cooler lines to the radiator. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement (See: Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 3014 Oil Cooler: Service and Repair Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement Removal Procedure 1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe. 2. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 3. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed. Discard the retaining rings. 4. Remove the engine oil cooler line from the quick connector fitting at the radiator. Refer to Engine Oil Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Engine Oil Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection). Pull the lines straight out from the connectors. 5. Clean all of the components in a suitable solvent, and dry them with compressed air. 6. Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction. Replace parts as necessary. Installation Procedure Note: When performing the following procedure, do not reuse the old retaining rings. Replace the old retaining rings with new ones. Do not install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting. 1. Install a new retaining ring into each quick connector fitting. 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 3015 3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 3016 5. Install the engine oil cooler line into the quick connector fitting until a click is heard or felt. Pull back on the engine oil cooler lines to ensure a proper connection. Note: Do not manually depress the retaining clip when installing the plastic cap. 6. Snap the plastic cap onto the quick connect fitting. 7. Ensure that the plastic cap is fully seated against the fitting. 8. Ensure that no gap is present between the cap and the fitting. 9. Inspect and fill the engine oil to the proper level. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up Oil Filter: Customer Interest Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 3025 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up Oil Filter: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 10-06-01-007C > Feb > 11 > Engine - Valve Lifter Tick Noise At Start Up > Page 3031 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 07-06-01-016B > Jul > 09 > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: All Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Filter: > 07-06-01-016B > Jul > 09 > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: All Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 3041 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to drain completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and inspect the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 3042 10. Position the drain pan under the oil filter (437). 11. Remove the oil filter. 12. Ensure that the oil filter gasket is still on the old filter if not, remove the oil filter gasket from the oil pan. Installation Procedure 1. Apply clean engine oil to the NEW oil filter seal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW oil filter (437) and tighten to 30 Nm (22 lb ft). 3. Tighten the oil pan drain plug (430) to 25 Nm (18 lb ft). 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities (See: Maintenance/Specifications) and Fluid and Lubricant Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 3043 Recommendations (USA and Canada) (See: Maintenance). 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Adapter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. For 1500 series vehicles, remove the oil pan skid plate bolts and skid plate, if equipped. 3. For 2500 series vehicles, loosen the 2 rear oil pan skid plate bolts, remove the 2 front oil pan skid plate bolts and skid plate, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 3047 4. Place a suitable drain pan under the oil filter. 5. Remove the oil filter (437). 6. Remove the oil filter adapter (438). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 3048 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the oil filter adapter (438). Tighten the adapter to 55 Nm (40 lb ft). 2. Lubricate the oil filter seal with clean engine oil. 3. Install the oil filter (437). Tighten the filter to 30 Nm (22 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 3049 4. For 2500 series vehicles, position the oil pan skid plate and tighten until snug the 2 rear oil pan skid plate bolts, install the 2 front oil pan skid plate bolts, if equipped. Tighten the bolts to 28 Nm (21 lb ft). 5. For 1500 series vehicles, position the oil pan skid plate and install the oil pan skid plate bolts, if equipped. Tighten the bolts to 28 Nm (21 lb ft). 6. Lower the vehicle. 7. Refill the engine oil. Refer to Approximate Fluid Capacities (See: Maintenance/Specifications) and/or Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). 8. Start the engine and inspect for leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement Oil Pan: Service and Repair Oil Pan Cover Replacement Oil Pan Cover Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the oil pan cover bolts (435), cover (434), and gasket (433). Discard the gasket. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position a NEW oil pan cover gasket (433) and the cover (434) to the oil pan and install the bolts (435). Tighten the bolts to 12 Nm (106 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3054 2. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3055 Oil Pan: Service and Repair Oil Pan Replacement Oil Pan Replacement (4WD) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. For 1500 series vehicles, remove the oil pan skid plate bolts and skid plate, if equipped. 3. For 2500 series vehicles, loosen the 2 rear oil pan skid plate bolts, remove the 2 front oil pan skid plate bolts and skid plate, if equipped. 4. Remove the front differential carrier. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair)Differential Carrier Assembly Replacement (2500 4WD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair). 5. Unbolt the steering rack and hang downward. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3056 6. Place a suitable drain pan under the oil pan drain plug. 7. Remove the oil pan drain plug (430). 8. Allow the oil pan to drain completely. 9. Re-install the oil pan drain plug until snug. 10. Place the drain pan under the oil filter. 11. Remove the oil filter (437). 12. Allow the oil to drain completely. 13. Re-install the oil filter until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3057 14. Remove the right side transmission cover bolt. 15. Remove the left side transmission cover bolt and cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3058 16. For 1500 series vehicles, remove the crossbar bolts/nuts and crossbar. 17. For 2500 series vehicles, remove the crossbar bolts/nuts and crossbar. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3059 18. For vehicles with a 4L60-E/4L70-E automatic transmission, remove the 2 lower transmission bolts. 19. For vehicles with a 4L80-E automatic transmission, remove the 2 lower transmission bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3060 20. For vehicles with a 6L80-E automatic transmission, remove the lower left transmission bolt. 21. For vehicles with a 6L80-E automatic transmission, remove the lower right transmission stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3061 22. Disconnect the engine harness electrical connector (4) from the oil level sensor. 23. Remove the engine harness clip (3) from the transmission oil cooler line bracket. 24. Remove the battery cable channel bolt (2). 25. Slide the channel pin (3) out of the oil pan tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3062 26. For vehicles with a 4L60-E/4L70-E automatic transmission, remove the oil cooler lines from the clip (1), if equipped. 27. For vehicles with a 4L80-E automatic transmission, remove the oil cooler lines from the clip (1), if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3063 28. For vehicles with a 6L80-E automatic transmission, remove the oil cooler lines from the clip (1). 29. Remove the transmission oil cooler line clip bolt and clip from the oil pan. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3064 30. Remove the oil pan bolts. 31. Remove the oil pan. 32. If reusing the oil pan perform the following steps, otherwise proceed to step 3 of the installation procedure. Note: DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the openings as required. 33. Drill out the oil pan gasket rivets (2), if necessary. 34. Remove the oil pan gasket (1) from the pan. 35. Discard the oil pan gasket. 36. Discard the rivets, if necessary. Installation Procedure Note: * The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide mounting points for the transmission bellhousing. To ensure the rigidity of the powertrain and correct transmission alignment, it is important that the rear of the block and the rear of the oil pan must NEVER protrude beyond the engine block and transmission bellhousing plane. * Do not reuse the oil pan gasket. * It is not necessary to rivet the NEW gasket to the oil pan. 1. If reusing the oil pan perform the following step, otherwise proceed to step 3. Note: Be sure to align the oil gallery passages in the oil pan and engine block properly with the oil pan gasket. 2. Place a NEW oil pan gasket onto the oil pan. 3. Apply a 5 mm (0.20 in) bead of sealant, 20 mm (0.80 in) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3065 4. Apply a 5 mm (0.20 in) bead of sealant, 20 mm (0.8 in) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). 5. Install 1 oil pan bolt into a oil pan bolt hole and up through the gasket. 6. Position and install the oil pan and the rest of the oil pan bolts. 7. Tighten the oil pan bolts until snug. 8. For vehicles with a 6L80-E automatic transmission, position the oil cooler bracket and install the lower right transmission stud until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3066 9. For vehicles with a 6L80-E automatic transmission, install the lower left transmission bolt until snug. 10. For vehicles with a 4L80-E automatic transmission, install the 2 lower transmission bolts until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3067 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 11. For vehicles with a 4L60-E/4L70-E automatic transmission, install the 2 lower transmission bolts until snug. 1. Tighten the oil pan and oil pan-to-oil pan front cover bolts to 25 Nm (18 lb ft). 2. Tighten the oil pan-to-rear cover bolts to 12 Nm (106 lb in). 3. Tighten the transmission bolts/stud to 50 Nm (37 lb ft). 12. Position the transmission oil cooler line clip and install the bolt to the oil pan. Tighten the bolt to 9 Nm (80 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3068 13. For vehicles with a 6L80-E automatic transmission, install the oil cooler lines to the clip (1). 14. For vehicles with a 4L80-E automatic transmission, install the oil cooler lines to the clip (1), if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3069 15. For vehicles with a 4L60-E/4L70-E automatic transmission, install the oil cooler lines to the clip (1), if equipped. 16. Position the channel and slide the channel pin (3) into the oil pan tab. 17. Install the battery cable channel bolt (2). Tighten the bolt to 12 Nm (106 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3070 18. Connect the engine harness electrical connector (4) to the oil level sensor. 19. Install the engine harness clip (3) to the transmission oil cooler line bracket. 20. For both the 1500 and 2500 series, perform the following steps prior to installing the crossbar bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolts with denatured alcohol or equivalent and allow to dry. 3. Apply threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the bolt threads. 21. For 2500 series vehicles, install the crossbar and crossbar bolts/nuts. Tighten the nuts to 120 Nm (89 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3071 22. For 1500 series vehicles, install the crossbar and crossbar bolts/nuts. Tighten the nuts to 100 Nm (74 lb ft). 23. Position the left side transmission cover and install the cover bolt. Tighten the bolt to 12 Nm (106 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3072 24. Install the right side transmission cover bolt. Tighten the bolt to 12 Nm (106 lb in). 25. If reusing the old oil pan remove the old oil filter and install a NEW oil filter. 26. Lubricate the NEW oil filter seal with clean engine oil. 27. Install the NEW oil filter (437). Tighten the oil filter to 30 Nm (22 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3073 28. Ensure that the oil pan drain plug (430) is tight. Tighten the drain plug to 25 Nm (18 lb ft). 29. Install the front differential carrier. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair)Differential Carrier Assembly Replacement (2500 4WD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair). 30. Raise the steering rack in place and install the steering rack bolts. * Tighten the left side steering rack bolts to 200 Nm (148 lb ft). * Tighten the right side steering rack bolts to 100 Nm (74 lb ft). 31. For 2500 series vehicles, position the oil pan skid plate and tighten until snug the 2 rear oil pan skid plate bolts, install the 2 front oil pan skid plate bolts, if equipped. Tighten the bolts to 28 Nm (21 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Cover Replacement > Page 3074 32. For 1500 series vehicles, position the oil pan skid plate and install the oil pan skid plate bolts, if equipped. Tighten the bolts to 28 Nm (21 lb ft). 33. Lower the vehicle. 34. Fill the engine with NEW engine oil. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance) and Approximate Fluid Capacities (See: Maintenance/Specifications). 35. Start the engine and inspect for leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Page 3078 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Page 3079 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Page 3080 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Page 3081 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Page 3082 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum - Hot .......................................................................................................................................................41 kPa at 1,000 engine RPM 6 psig at 1,000 engine RPM ...................................................................................................................................................124 kPa at 2,000 engine RPM 18 psig at 2,000 engine RPM ...................................................................................................................................................165 kPa at 4,000 engine RPM 24 psig at 4,000 engine RPM Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 3087 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Tools Required * EN-47971 Oil Pressure Gauge Adapter * J 21867 Pressure Gauge 1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gauge or light. 4. Listen for a noisy valve train or a knocking noise. 5. Inspect for the following conditions: * Oil diluted by water or glycol antifreeze Refer to Coolant in Engine Oil (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Coolant in Engine Oil). * Foamy oil, which may be caused by a cut or damaged oil pump screen O-ring seal 6. Remove the oil filter and install the EN-47971 (1). 7. Install the J 21867 (2), or equivalent to the EN-47971 (1). 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to Engine Mechanical Specifications (RPO L20 VIN A) (See: Specifications/Service Limits & General Specifications )Engine Mechanical Specifications (RPO L96 VIN G) (See: Specifications/Service Limits & General Specifications/Engine Mechanical Specifications/6.0L RPO L96 VIN G)Engine Mechanical Specifications (RPO L9H) (See: Specifications/Service Limits & General Specifications)Engine Mechanical Specifications (RPO LC9 VIN 3) ()Engine Mechanical Specifications (RPO LMG VIN 0) ()Engine Mechanical Specifications (RPO LY6 VIN K) (See: Specifications/Service Limits & General Specifications/Engine Mechanical Specifications/6.0L RPO LY6 VIN K). 10. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the following conditions: * Improper operation of the active fuel management oil pressure relief valve Refer to Cylinder Deactivation (Active Fuel Management) Oil Pressure Relief Valve Diagnosis and Testing (See: Testing and Inspection/Component Tests and General Diagnostics). * Oil pump worn or dirty Refer to Oil Pump Cleaning and Inspection (See: Service and Repair/Overhaul/36. Oil Pump Cleaning and Inspection). * Oil pump-to-engine block bolts loose Refer to Oil Pump, Screen and Crankshaft Oil Deflector Installation (See: Service and Repair/Overhaul/95. Oil Pump, Screen and Crankshaft Oil Deflector Installation). * Oil pump screen loose, plugged, or damaged * Oil pump screen O-ring seal missing or damaged * Malfunctioning oil pump pressure relief valve Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 3088 * Excessive bearing clearance * Cracked, porous, or restricted oil galleries * Oil gallery plugs missing or incorrectly installed Refer to Engine Block Plug Installation (See: Service and Repair/Overhaul/45. Engine Block Plug Installation). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 3093 Intake Manifold: Specifications Intake Manifold Bolts - First Pass in Sequence.................................................................................... ...........................................................5 Nm (44 lb in.) Intake Manifold Bolts - Final Pass in Sequenc e............................................................................................................................................10 Nm (89 lb in.) Throttle Body Bolts............................................................................................................... ........................................................................10 Nm (89 lb in.) Throttle Body Nuts............................ ............................................................................................................................................................1 0 Nm (89 lb in.) Throttle Body Studs.................................................................................................... .....................................................................................6 Nm (53 lb in.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement Intake Manifold: Service and Repair Upper Intake Manifold Sight Shield Replacement Upper Intake Manifold Sight Shield Replacement Removal Procedure 1. Open the hood. 2. Grasp the front of the intake manifold sight shield and lift up disengaging the grommets from the studs. 3. Remove the intake manifold sight shield from the retainer slots. 4. Remove the intake manifold sight shield retainer bolts and retainer, if required. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3096 1. Position the intake manifold sight shield on top of the intake manifold, aligning the holes, if required. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the intake manifold sight shield retainer bolts, if required. Tighten the bolts to 5 Nm (44 lb in). 3. Install the intake manifold sight shield tabs into the slots in the retainer. 4. Align the intake manifold sight shield grommets with the studs. 5. Gently push down on the intake manifold sight shield over the grommets, seating the intake manifold sight shield. 6. Close the hood. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3097 Intake Manifold: Service and Repair Intake Manifold Replacement Intake Manifold Replacement (With AFM) Intake Manifold Replacement (With AFM) Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Remove the generator. Refer to Generator Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair )Generator Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 3. Remove the engine harness retainer nut (1). 4. Remove the engine harness retainer from the stud and locator. 5. Disconnect the engine harness electrical connector (2) from the evaporative emission (EVAP) canister purge solenoid. 6. Disconnect the engine wiring harness electrical connector (4) from the manifold absolute pressure (MAP) sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3098 7. Remove the connector position assurance (CPA) retainer. 8. Disconnect the engine harness electrical connector from the ignition coil harness electrical connector. 9. Disconnect the engine harness electrical connectors from the left side fuel injectors. 10. Remove the engine harness clip (4) from the ignition coil bracket stud. 11. Remove the CPA retainer (2). 12. Disconnect the engine harness electrical connector (1) from the ignition coil harness electrical connector. 13. Disconnect the engine harness electrical connector (3) from the throttle actuator. 14. Remove the engine harness clip (4) from the generator battery jumper cable. 15. Remove the engine harness clip (6) from the ignition coil bracket stud. 16. Disconnect the engine harness electrical connectors (7) from the right side fuel injectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3099 17. Remove the engine harness clip (1) and bolt (3). 18. Disconnect the engine harness electrical connector (2) from the engine coolant temperature (ECT) sensor. 19. Gather the engine harness branches and tie the harness up out of the way to the cowl panel. 20. Reposition the brake booster vacuum hose clamp at the booster, if necessary. 21. Remove the brake booster vacuum hose from the booster fitting, if necessary. 22. Secure the brake booster vacuum hose to the intake manifold if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3100 23. Disconnect the EVAP canister purge tube (1) quick connect fitting from the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 24. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 25. Remove the positive crankcase ventilation (PCV) hose from the intake manifold fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3101 26. Loosen the intake manifold bolts. 27. Remove the intake manifold (500). 28. Remove and discard the intake manifold gaskets (514). 29. Cover the cylinder head passages in order to prevent dirt or debris from entering the passages. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3102 30. If replacing the intake manifold, perform the following steps, otherwise proceed to step 21 of the installation procedure. 31. Place the intake manifold on a clean work surface. 32. Reposition the brake booster vacuum hose clamp at the intake manifold. 33. Remove the brake booster vacuum hose from the intake manifold nipple. 34. Remove the upper intake manifold cover nut. 35. Remove the upper intake manifold cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3103 36. Remove the manifold absolute pressure (MAP) sensor retainer. 37. Remove the MAP sensor. 38. Disconnect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 39. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail. 40. Remove the EVAP tube and purge solenoid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3104 41. Remove the throttle body bolts/nuts. 42. Remove the throttle body. 43. Remove and discard the throttle body gasket. 44. Remove the fuel rail bolts. Note: Lift evenly on both sides of the fuel rail until all injectors are removed from their bores. 45. Remove the fuel rail. 46. Remove and discard the fuel injector lower O-ring seals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3105 Note: Evenly push in the RED collar in order to remove the nipple. 47. Remove the brake booster vacuum hose nipple. Installation Procedure 1. If the intake manifold was replaced perform the following steps, otherwise proceed to step 21. Note: Evenly push in the RED collar in order to install the nipple. 2. Install the brake booster vacuum hose nipple to the NEW intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3106 3. Install NEW fuel injector lower O-ring seals onto the injectors. 4. Lubricate the NEW O-ring seals with clean engine oil. Note: Push down firmly on both sides of the rail until all the injectors have been seated into their bores. 5. Install the fuel rail. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the fuel rail bolts. Tighten the bolts to 10 Nm (89 lb in). 7. Install a NEW throttle body gasket to the intake manifold. 8. Install the throttle body. 9. Install the throttle body bolts/nuts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3107 Tighten the bolts/nuts to 10 Nm (89 lb in). 10. Install the EVAP tube and purge solenoid. 11. Install the EVAP canister purge solenoid to the fuel rail bracket and engage the retainer. 12. Connect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 13. Lubricate the MAP sensor seal with clean engine oil. 14. Install the MAP sensor. 15. Install the MAP sensor retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3108 16. Install the upper intake manifold cover. 17. Install the upper intake manifold cover nut until snug. 18. Install the brake booster vacuum hose to the intake manifold nipple. 19. Position the brake booster vacuum hose clamp at the intake manifold. 20. Secure the brake booster vacuum hose to the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3109 21. Install NEW intake manifold gaskets (514) to the intake manifold. 22. Remove the covers from the cylinder head passages. 23. Install the intake manifold (500). Note: The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness. 24. Tighten the intake manifold bolts (512) until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3110 25. Tighten the intake manifold bolts to specifications. * Tighten the bolts a first pass in the sequence shown to 5 Nm (44 lb in). * Tighten the bolts a final pass in the sequence shown to 10 Nm (89 lb in). 26. Position and install the PCV hose to the intake manifold fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3111 27. Connect the fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 28. Connect the EVAP canister purge tube (1) quick connect fitting to the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 29. Unsecure the brake booster vacuum hose from the intake manifold, if removed. 30. Install the brake booster vacuum hose to the booster fitting, if removed. 31. Position the brake booster vacuum hose clamp at the booster, if removed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3112 32. Untie the engine harness branches from the cowl panel and position over the engine. 33. Connect the engine harness electrical connector (2) to the ECT sensor. 34. Position the engine harness clip (1) to the generator bracket and install the bolt (3). Tighten the bolt to 9 Nm (80 lb in). 35. Connect the engine harness electrical connectors (7) to the right side fuel injectors. 36. Install the engine harness clip (6) to the ignition coil bracket stud. 37. Install the engine harness clip (4) to the generator battery jumper cable. 38. Connect the engine harness electrical connector (3) to the throttle actuator. 39. Connect the engine harness electrical connector (1) to the ignition coil harness electrical connector. 40. Install the CPA retainer (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3113 41. Install the engine harness clip (4) to the ignition coil bracket stud. 42. Connect the engine harness electrical connectors to the left side fuel injectors. 43. Connect the engine harness electrical connector to the ignition coil harness electrical connector. 44. Install the CPA retainer. 45. Connect the engine wiring harness electrical connector (4) to the MAP sensor. 46. Connect the engine harness electrical connector (2) to the EVAP canister purge solenoid. 47. Install the engine harness retainer to the stud and locator pin. 48. Install the engine harness retainer nut (1). Tighten the nut to 5 Nm (44 lb in). 49. Install the generator. Refer to Generator Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair )Generator Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 50. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3114 Intake Manifold Replacement (Without AFM) Intake Manifold Replacement (Without AFM) Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Remove the generator. Refer to Generator Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair )Generator Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 3. Remove the engine harness retainer nut (1). 4. Remove the engine harness retainer from the stud and locator pin. 5. Disconnect the engine harness electrical connector (2) from the evaporative emission (EVAP) canister purge solenoid. 6. Disconnect the engine wiring harness electrical connector (4) from the manifold absolute pressure (MAP) sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3115 7. Remove the connector position assurance (CPA) retainer (1). 8. Disconnect the engine harness electrical connector (1) from the ignition coil harness electrical connector. 9. Disconnect the engine harness electrical connectors (3) from the left side fuel injectors. 10. Remove the engine harness clip (4) from the ignition coil bracket stud. 11. Remove the CPA retainer (2). 12. Disconnect the engine harness electrical connector (1) from the ignition coil harness electrical connector. 13. Disconnect the engine harness electrical connector (3) from the throttle actuator. 14. Remove the engine harness clip (4) from the generator battery jumper cable. 15. Remove the engine harness clip (6) from the ignition coil bracket stud. 16. Disconnect the engine harness electrical connectors (7) from the right side fuel injectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3116 17. Remove the engine harness clip (1) bolt (3). 18. Disconnect the engine harness electrical connector (2) from the engine coolant temperature (ECT) sensor. 19. Gather the engine harness branches and tie the harness up out of the way to the cowl panel. 20. Reposition the brake booster vacuum hose clamp at the booster. 21. Remove the brake booster vacuum hose from the booster fitting. 22. Secure the brake booster vacuum hose to the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3117 23. Disconnect the EVAP canister purge tube (1) quick connect fitting from the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 24. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 25. Remove the positive crankcase ventilation (PCV) hose from the intake manifold fitting. 26. Position the hose out of the way. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3118 27. Loosen the intake manifold bolts (512). Note: The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness. 28. Remove the intake manifold (500). 29. Cover the cylinder head passages in order to prevent dirt or debris from entering the passages. 30. Remove and discard the intake manifold gaskets (514). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3119 31. If replacing the intake manifold, perform the following steps, otherwise proceed to step 21 of the installation procedure. 32. Place the intake manifold on a clean work surface. 33. Reposition the brake booster vacuum hose clamp at the intake manifold. 34. Remove the brake booster vacuum hose from the intake manifold nipple. 35. Remove the upper intake manifold cover nut. 36. Remove the upper intake manifold cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3120 37. Remove the manifold absolute pressure (MAP) sensor retainer. 38. Remove the MAP sensor. 39. Disconnect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 40. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail. 41. Remove the EVAP tube and purge solenoid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3121 42. Remove the throttle body bolts/nuts. 43. Remove the throttle body. 44. Remove and discard the throttle body gasket. 45. Remove the fuel rail bolts. Note: Lift evenly on both sides of the fuel rail until all injectors are removed from their bores. 46. Remove the fuel rail. 47. Remove and discard the fuel injector lower O-ring seals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3122 Note: Evenly push in the RED collar in order to remove the nipple. 48. Remove the brake booster vacuum hose nipple. Installation Procedure 1. If the intake manifold was replaced perform the following steps, otherwise proceed to step 21. Note: Evenly push in the RED collar in order to install the nipple. 2. Install the brake booster vacuum hose nipple to the NEW intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3123 3. Install NEW fuel injector lower O-ring seals onto the injectors. 4. Lubricate the NEW O-ring seals with clean engine oil. Note: Push down firmly on both sides of the rail until all the injectors have been seated into their bores. 5. Install the fuel rail. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the fuel rail bolts and tighten to 10 Nm (89 lb in). 7. Install a NEW throttle body gasket to the intake manifold. 8. Install the throttle body. 9. Install the throttle body bolts/nuts and tighten to 10 Nm (89 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3124 10. Install the EVAP tube and purge solenoid. 11. Install the EVAP canister purge solenoid to the fuel rail bracket and engage the retainer. 12. Connect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 13. Lubricate the MAP sensor seal with clean engine oil. 14. Install the MAP sensor. 15. Install the MAP sensor retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3125 16. Install the upper intake manifold cover. 17. Install the upper intake manifold cover nut until snug 18. Install the brake booster vacuum hose to the intake manifold nipple. 19. Position the brake booster vacuum hose clamp at the intake manifold. 20. Secure the brake booster vacuum hose to the intake manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3126 21. Install NEW intake manifold gaskets (514) to the intake manifold. 22. Remove the covers from the cylinder head passages. 23. Install the intake manifold (500). Note: The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness. 24. Tighten the intake manifold bolts (512) until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3127 25. Tighten the intake manifold bolts to specifications. * Tighten the bolts a first pass in the sequence shown to 5 Nm (44 lb in). * Tighten the bolts a final pass in the sequence shown to 10 Nm (89 lb in). 26. Position and install the PCV hose to the intake manifold fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3128 27. Connect the fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 28. Connect the EVAP canister purge tube (1) quick connect fitting to the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 29. Unsecure the brake booster vacuum hose from the intake manifold. 30. Install the brake booster vacuum hose to the booster fitting. 31. Position the brake booster vacuum hose clamp at the booster. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3129 32. Untie the engine harness branches from the cowl panel and position over the engine. 33. Connect the engine harness electrical connector (2) to the ECT sensor. 34. Position the engine harness clip (1) to the generator bracket and install the bolt (3). Tighten the bolt to 9 Nm (80 lb in). 35. Connect the engine harness electrical connectors (7) to the right side fuel injectors. 36. Install the engine harness clip (6) to the ignition coil bracket stud. 37. Install the engine harness clip (4) to the generator battery jumper cable. 38. Connect the engine harness electrical connector (3) to the throttle actuator. 39. Connect the engine harness electrical connector (1) to the ignition coil harness electrical connector. 40. Install the CPA retainer (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3130 41. Install the engine harness clip (4) to the ignition coil bracket stud. 42. Connect the engine harness electrical connectors (3) to the left side fuel injectors. 43. Connect the engine harness electrical connector (1) to the ignition coil harness electrical connector. 44. Install the CPA retainer (1). 45. Connect the engine wiring harness electrical connector (4) to the MAP sensor. 46. Connect the engine harness electrical connector (2) to the EVAP canister purge solenoid. 47. Install the engine harness retainer to the stud and locator pin. 48. Install the engine harness retainer nut (1) and tighten to 5 Nm (44 lb in). 49. Install the generator. Refer to Generator Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair )Generator Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 50. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3131 Intake Manifold: Service and Repair Engine Block Valley Cover Replacement Engine Block Valley Cover Replacement Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: )Intake Manifold Replacement (With AFM) (See: ). 2. Remove the engine valley cover bolts (506). 3. Remove the engine valley cover (555) and gasket (556). 4. Remove the O-ring seals (537) from the cover. 5. Remove the oil pressure sensor (706) and washer (707). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3132 Note: All gasket surfaces should be free of oil or other foreign material during assembly. 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the oil pressure sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install a NEW washer (707) and the oil pressure sensor (706). Tighten the sensor to 35 Nm (26 lb ft). 3. Lubricate the O-ring seals with clean engine oil. 4. Install the O-ring seals (537) to the cover. 5. Set the engine valley cover (555) onto the engine. 6. Install the engine valley cover bolts (506). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3133 Tighten the bolts to 25 Nm (18 lb ft). 7. Install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: )Intake Manifold Replacement (With AFM) (See: ). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3134 Intake Manifold: Service and Repair Upper Intake Manifold Cover Replacement Upper Intake Manifold Cover Replacement Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: )Intake Manifold Replacement (With AFM) (See: ). 2. Reposition the brake booster vacuum hose clamp at the intake manifold. 3. Remove the brake booster vacuum hose from the intake manifold nipple. 4. Remove the upper intake manifold cover nut. 5. Remove the upper intake manifold cover. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Upper Intake Manifold Sight Shield Replacement > Page 3135 1. Install the upper intake manifold cover. 2. Install the upper intake manifold cover nut until snug 3. Install the brake booster vacuum hose to the intake manifold nipple. 4. Position the brake booster vacuum hose clamp at the intake manifold. 5. Install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: )Intake Manifold Replacement (With AFM) (See: ). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement Special Tools J 41479 Crankshaft Rear Oil Seal Installer Removal Procedure 1. Remove the automatic transmission flexplate, refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair). 2. Remove and discard the crankshaft rear oil seal (141). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 3140 Important: For proper orientation, note the installation direction of the oil seal. The oil seal is a reverse-lip design. The part number is applied to the outside face of the seal, as shown. 1. Inspect the seal and identify the part number markings for proper orientation. 2. Install the J 41479 cone (2) and bolts onto the rear of the crankshaft. 3. Tighten the bolts until snug. Do not overtighten. 4. Install the rear oil seal onto the tapered cone (2) and push the seal to the rear seal bore. Install the oil seal with the part number markings facing away from the engine. 5. Thread the J 41479 threaded rod into the tapered cone until the tool (1) contacts the oil seal. 6. Align the oil seal into the tool (1). 7. Rotate the handle of the tool (1) clockwise until the seal enters the rear cover and bottoms into the cover bore. 8. Remove the J 41479 . 9. Install the automatic transmission flexplate. refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement (With LY6) Special Tools J 41478 Crankshaft Front Oil Seal Installer Removal Procedure 1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). 2. Remove the crankshaft front oil seal (140) from the front cover. Installation Procedure Note: * Do not lubricate the oil seal sealing surface. * Do not reuse the crankshaft front oil seal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 3144 1. Lubricate the outer edge of the oil seal (140) with clean engine oil. 2. Lubricate the front cover oil seal bore with clean engine oil. 3. Install the crankshaft front oil seal (140) onto the J 41478 guide. 4. Install the J 41478 threaded rod (with nut, washer, guide, and oil seal) into the end of the crankshaft. 5. Use the J 41478 in order to install the oil seal into the cover bore. 1. Use a wrench and hold the hex on the installer bolt. 2. Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore. 3. Remove the J 41478 . 4. Inspect the oil seal for proper installation. The oil seal should be installed evenly and completely into the front cover bore. 6. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Special Tools * J 22794 Spark Plug Port Adapter * J 38606 Valve Spring Compressor Removal Procedure 1. Remove the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See: Camshaft, Lifters and Push Rods/Rocker Arm Assembly/Service and Repair). 2. Disconnect the spark plug wire at the spark plug. * Twist each plug wire boot 1/2 turn. * Pull only on the boot in order to remove the wire from the spark plug. Note: Remove the spark plugs from the cylinder head with the engine at room temperature. 3. Loosen the spark plug 1 or 2 turns. 4. Brush or air blast away any dirt or debris from around the spark plug. 5. Remove the spark plug. 6. Install the J 22794 into the spark plug hole. 7. Attach an air hose to the J 22794 . 8. Apply compressed air to the J 22794 in order to hold the valves in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 3148 9. Use the J 38606 in order to compress the valve spring. 10. Remove the valve stem keys (225). 11. Carefully release the valve spring tension. 12. Remove the J 38606 . 13. Remove the valve spring cap (224). 14. Remove the valve spring (223). 15. Remove the valve stem oil seal (222). 16. Remove the valve (228). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 3149 1. Clean the cylinder head valve spring seat area. 2. Lubricate the valve guide and valve stem oil seal with clean engine oil. 3. Install the valves (228) into the proper port. 4. Install the valve stem oil seal (222). 5. Install the valve spring (223). 6. Install the valve spring cap (224). 7. Compress the valve spring using the J 38606 . 8. Install the valve keys. * Use grease in order to hold the valve keys in place. * Make sure the keys seat properly in the groove of the valve stem. * Carefully release the valve spring pressure, making sure the valve keys stay in place. * Remove the J 38606 . * Tap the end of the valve stem with a plastic faced hammer to seat the keys, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 3150 9. Remove the J 22794 from the spark plug port. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 10. Hand start the spark plug. Tighten the spark plug to 15 Nm (11 lb ft). 11. Install the spark plug wires at the ignition coil. 12. Install the spark plug wire to the spark plug. 13. Inspect the wires for proper installation: * Push sideways on each boot in order to check for proper installation. * Reinstall any loose boot. 14. Install the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See: Camshaft, Lifters and Push Rods/Rocker Arm Assembly/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 3155 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 3156 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 3157 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 3158 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 3159 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Position (CMP) Actuator Solenoid Valve - First Pass...................................................................................................................65 Nm (48 lb ft.) Camshaft Position (CMP) Actuator Solenoid Valve - Final Pass............................................................................................................................90 degrees Camshaft Retainer Bolts - Hex Head Bolts.......................................................................................... ..........................................................25 Nm (18 lb ft.) Camshaft Retainer Bolts - TORX Head Bolts................................................................................................................................................15 Nm (11 lb ft.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Timing Chain, Crankshaft Sprocket, Camshaft Position Actuator, and Solenoid Valve Replacement Special Tools * EN 46330 Timing Belt Tensioner Retaining Pin * J 8433 Two Jaw Puller * J 41478 Crankshaft Front Oil Seal Installer * J 41558 Crankshaft Sprocket Remover * J 41665 Crankshaft Balancer and Sprocket Installer * J 41816-2 Crankshaft End Protector * J 42386-A Flywheel Holding Tool * J 45059 Angle Meter Removal Procedure 1. Remove the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil Pump/Service and Repair). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Ensure that the teeth of the J 42386-A 2. Rotate the crankshaft sprocket until the camshaft position (CMP) actuator alignment mark (1) and the crankshaft sprocket alignment mark (2) are aligned. 3. Install the J 42386-A . Tighten the J 42386-A . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3167 4. Remove and discard the CMP actuator solenoid valve (234). 5. Loosen and separate the CMP actuator and timing chain from the camshaft. Position your fingers behind the actuator sprocket and pull the actuator away from the front of the camshaft. Never pull on the reluctor wheel when attempting to remove the actuator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3168 Caution: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves. 6. Remove the CMP actuator (235) and timing chain (208). 7. Insert and secure a tie strap (1) through the center of the actuator and over the reluctor wheel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3169 8. Remove the timing chain tension bolts (231) and tensioner (232). 9. Using the J 41816-2 (1), the J 41558 (2), bolts (3) and the J 8433 (4) in order to remove the crankshaft sprocket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3170 10. Remove the crankshaft sprocket (207). 11. Remove the crankshaft sprocket key, if required. Installation Procedure 1. Install the key into the crankshaft keyway, if previously removed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3171 2. Tap the key (122) into the keyway until both ends of the key bottom onto the crankshaft. 3. Install the crankshaft sprocket (207) onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3172 4. Use the J 41478 (1) and the J 41665 (2) in order to install the crankshaft sprocket. Install the sprocket onto the crankshaft until fully seated against the crankshaft flange. 5. Compress the timing chain tensioner guide and install the EN 46330 . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3173 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the timing chain tensioner (232) and bolts (231). Tighten the bolts to 25 Nm (18 lb ft). Note: * Properly locate the CMP actuator onto the locating pin of the camshaft. * The sprocket teeth and timing chain teeth must mesh. * The camshaft and the crankshaft sprocket alignment MUST be aligned properly. * Do not use the CMP solenoid valve again. Install a NEW CMP valve during assembly. 7. Identify the alignment hole (1) in the rear face of the CMP actuator and the locating pin (2) on the front face of he camshaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3174 8. Align the CMP actuator so the timing mark is in the 6 o'clock position. 9. Install the CMP actuator (235) and timing chain (208). Align the hole in the face of the CMP actuator with the locating pin on the front face of the camshaft. Warning Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3175 Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. 10. Use care to install the actuator completely onto the front of the camshaft. Position your fingers onto the face of the actuator sprocket and push the actuator onto the front of the camshaft. Never push on the reluctor wheel when attempting to install the actuator. 11. Place a straight edge across the front face of the engine block and inspect for proper installation of the CMP actuator and timing chain. With the CMP actuator properly and completely installed onto the front of the camshaft, the timing chain will not protrude beyond the front face of the engine block. 12. Install a NEW CMP actuator valve (234). With the CMP actuator properly positioned onto the camshaft, the CMP actuator solenoid valve can be threaded completely into the camshaft using light hand pressure. Tighten by hand until snug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3176 13. Inspect the sprockets for proper alignment. The mark on the CMP (1) actuator sprocket should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. 14. Remove the EN 46330 . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3177 15. Tighten the CMP actuator bolt. 1. Tighten the bolt a first pass to 65 Nm (48 lb ft). 2. Tighten the bolt a final pass an additional 90 degrees using J 45059 . 16. Remove the J 42386-A . 17. Install the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Timing Chain Tensioner Bolts.............................................................................................................. .........................................................25 Nm (18 lb ft.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Inspect the sprockets for proper alignment. The mark on the CMP (1) actuator sprocket should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Oil Pan To Front Cover Bolts ............................................................................................................... ....................................................... 25 Nm (18 lb ft) Engine Front Cover Bolts ................................... .......................................................................................................................................... 25 Nm (18 lb ft) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3187 Timing Cover: Service and Repair Engine Front Cover Replacement Special Tools J 41476 Front and Rear Cover Alignment Tool Removal Procedure 1. Remove the water pump. Refer to Water Pump Replacement (LU3) (See: Water Pump/Service and Repair)Water Pump Replacement (LMM) ( See: Water Pump/Service and Repair)Water Pump Replacement (V8) (See: Water Pump/Service and Repair). 2. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). 3. Disconnect the engine harness electrical connector (1) from the camshaft position (CMP) sensor wire harness electrical connector. 4. Remove the oil pan-to-front cover bolts (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3188 5. Remove the front cover bolts (501). 6. Remove the front cover (502) and gasket (503). 7. Discard the front cover gasket. 8. Remove the crankshaft front oil seal. 9. If replacing the engine front cover perform the following steps, otherwise proceed to step 10 of the installation procedure. 10. Remove the CMP sensor wire harness bolts (738). 11. Disconnect the CMP sensor wire harness from the CMP sensor. 12. Remove the CMP sensor wire harness (737). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3189 13. Remove the CMP sensor (703). 14. Remove the CMP actuator magnet bolts (751), and magnet (752). 15. Remove and discard the CMP actuator magnet gasket (753). Installation Procedure Note: * Do not reuse the crankshaft oil seal or front cover gasket. * Do not apply any type of sealant to the front cover gasket, unless specified. * The special tool in this procedure is used to properly center the front crankshaft front oil seal. - All gasket surfaces should be free of oil or other foreign material during assembly. - The crankshaft front oil seal MUST be centered in relation to the crankshaft. - An improperly aligned front cover may cause premature front oil seal wear and/or engine oil leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3190 1. If replacing the front cover perform the following steps, otherwise proceed to step 10. 2. Install a NEW CMP actuator magnet gasket (753) onto the magnet. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP actuator magnet (752) and bolts (751). Tighten the bolts to 12 Nm (106 lb in). 4. Inspect the CMP sensor O-ring seal for cuts or damage. If the seal is not cut or damaged, it may be reused. 5. Lubricate the O-ring seal (704) with clean engine oil. 6. Install the CMP sensor (703). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3191 7. Position the CMP sensor wire harness (737) to the front cover 8. Connect the CMP sensor wire harness to the CMP sensor. 9. Install the CMP sensor wire harness bolts (738). Tighten the bolts to 12 Nm (106 lb in). 10. Apply a 5 mm (0.20 in) bead of sealant, 20 mm (0.80 in) long to the oil pan to engine block junction. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). 11. Position the NEW engine front cover gasket (503) and front cover (502) to the engine. 12. Install the front cover bolts (501) until snug. Do not overtighten. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3192 13. Install the oil pan-to-front cover bolts (1) until snug. Do not over tighten. 14. Install J 41476 to the front cover. 15. Align the tapered legs of the J 41476 with the machined alignment surfaces on the front cover. 16. Install the crankshaft balancer bolt until snug. Do not overtighten. 1. Tighten the oil pan to front cover bolts to 25 Nm (18 lb ft). 2. Tighten the engine front cover bolts to 25 Nm (18 lb ft). 17. Remove the J 41476 . 18. Connect the engine harness electrical connector (1) to the CMP sensor wire harness electrical connector. 19. Install a NEW crankshaft front oil seal. Refer to Crankshaft Front Oil Seal Replacement (With LY6) (See: Seals and Gaskets/Front Crankshaft Seal/Service and Repair). 20. Install the water pump. Refer to Water Pump Replacement (LU3) (See: Water Pump/Service and Repair)Water Pump Replacement (LMM) ( Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3193 See: Water Pump/Service and Repair)Water Pump Replacement (V8) (See: Water Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Camshaft Position (CMP) Actuator System The camshaft position (CMP) actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation (EGR) control, a wider engine torque range, improved gas mileage, and improved engine idle stability. The CMP actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. For the 6.0 liter (LY6, L76) and the 6.2 liter (L92) engine, the Park position for the CMP actuator and camshaft is 8.5 degrees before top dead center (BTDC) or 17 crankshaft degrees BTDC. The engine control module (ECM) can only command the CMP actuator to retard the valve timing from the Park position or advance the valve timing back to the Park position. The total range of valve timing authority is 31 degrees camshaft rotation, or 62 degrees of crankshaft rotation. The control range is from the Park position of 8.5 degrees camshaft or 17 degrees crankshaft BTDC, to 22.5 degrees camshaft or 45 degrees crankshaft after top dead center (ATDC). CMP Actuator System Operation The camshaft position (CMP) actuator system is controlled by the control module. The control module sends a pulse width modulated 12-volt signal to a CMP actuator solenoid in order to control the amount of engine oil flow to a camshaft actuator passage. There are 2 different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The camshaft actuator is attached to the front of the camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position (CKP). Incorrect engine oil pressure (EOP), viscosity, temperature, engine oil level, or aftermarket engine oil additives can have an adverse affect on camshaft phaser performance. CMP Actuator Solenoid Circuit Diagnostics The engine control module (ECM) monitors the control circuit of the camshaft position (CMP) actuator solenoid for electrical faults. The control module has the ability to determine if a control circuit is open, shorted high, or shorted low. If the control module detects a fault with the CMP actuator solenoid control circuit, DTC P0010 will set. CMP Actuator System Performance Diagnostic The engine control module (ECM) monitors the performance of the camshaft position (CMP) actuator system by monitoring the calibrated desired position and the actual position of the camshaft through the 4X signal of the CMP sensor. If the difference between the actual and desired position is Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Page 3198 greater than a calibrated angle for a calibrated amount of time, DTC P0011 will set. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Service Precautions Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) Fuel Pressure: Testing and Inspection Fuel System Diagnosis (FPCM) Fuel System Diagnosis (FPCM) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for 2 seconds, unless the engine is in Crank or Run. While this voltage is being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure. The fuel system is an electronic returnless on-demand design. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump is contained by the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pump module contains a reverse flow check valve. The check valve maintains fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Reference Information Description and Operation Fuel System Description (See: Powertrain Management/Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH-48027 Digital Pressure Gauge * J 37287 Fuel Line Shut-off Adapter Circuit/System Verification Note: * Repair all fuel system related DTCs before performing this diagnostic, unless instructed here from a DTC diagnostic. * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. * DO NOT perform the Fuel System Diagnosis if the engine coolant temperature is above 60°C (150°F). High fuel pressure readings may result due to hot soak fuel boiling. With the engine OFF, the fuel pressure may increase beyond the pressure relief valves set point of 690 kPa = / -5 % (100 psi ±5 %). 1. Ignition OFF, all accessories OFF, install a CH-48027 . Refer to Fuel Pressure Gauge Installation and Removal (See: Fuel Pressure Gauge Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) > Page 3205 Installation and Removal). 2. Ignition ON, engine OFF, command the fuel pump ON with a scan tool. Verify the fuel pressure is between 345-690 kPa (50-100 psi) with the pump running. 3. Engine ON with the engine idling at normal operating temperature, the Fuel Rail Pressure Sensor parameter should read between 296.4-310.3 kPa (43-45 psi). Circuit/System Testing Note: * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, engine OFF, command the fuel pump ON with a scan tool and observe the fuel pressure gauge while the fuel pump is operating. Verify the fuel pressure is between 345-690 kPa (50-100 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 2. Verify that the fuel pressure, after the fuel pump is turned off, decreases to 500-599 kPa (72-87 psi), and does not decrease more than 34 kPa (5 psi) in 1 minute from that point. ‹› If the fuel pressure stays above 600 kPa (87 psi), replace the fuel pump module. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair ). 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 . 4. Ignition ON, command the fuel pump ON with a scan tool and bleed the air from the CH-48027 . 5. Command the fuel pump ON and then OFF with a scan tool. 6. Close the valve on the J 37287 . 7. Monitor the fuel pressure for 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module. 4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with the CH-48027 . The fuel pressure should not drop off during acceleration, cruise or hard cornering. ‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections 5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) > Page 3206 Fuel Pressure: Testing and Inspection Fuel Pressure Gauge Installation and Removal Fuel Pressure Gauge Installation and Removal Special Tools CH-48027 Digital Pressure Gauge Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions. Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) > Page 3207 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 3211 Idle Speed: Testing and Inspection Throttle/Idle Learn Description The engine control module (ECM) learns the airflow through the throttle body to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to throttle body coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned. An engine that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero. The idle may be unstable or a DTC may set if the learned values do not match the actual airflow. Conditions for Running the Throttle Learn Procedure Reset Procedure * DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set. * Ignition ON, engine OFF. * The vehicle speed sensor (VSS) is 0 km/h (0 mph). Learn Procedure * DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set. * The engine speed is between 450-4,000 RPM. * The manifold absolute pressure (MAP) is greater than 5 kPa. * The mass air flow (MAF) is greater than 2 g/s. * The ignition voltage is greater than 10 volts. Throttle Learn Reset Procedure (Performed after the throttle body is cleaned or replaced) 1. Ignition ON, engine OFF, perform the Idle Learn Reset in Module Setup with a scan tool. 2. Start the engine and monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation value should equal 0 percent and the engine should be idling at a normal idle speed. 3. Clear the DTCs and return to the diagnostic that referred you here. Learn Procedure (Performed after the ECM is flashed or replaced) Note: Do NOT perform this procedure if DTCs are set. Refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle). 1. Start and idle the engine for 3 minutes. 2. With a scan tool, monitor the Desired Idle Speed and the actual Engine Speed. 3. The ECM will start to learn the new idle cells and Desired Idle Speed should start to decrease. 4. Ignition OFF for 60 seconds. 5. Start and idle the engine for 3 minutes. 6. After the 3 minute run time the engine should be idling normal. Note: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. ‹› If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles. 7. After the drive cycle, the engine should be idling normally. ‹› If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 3212 8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that referred you here. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Resonator Outlet Duct Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair). 2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct. 3. Remove the radiator inlet hose clamp retainer from the outlet duct. 4. Loosen the air cleaner outlet duct clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 5. Loosen the air cleaner outlet duct clamp (2) at the throttle body. 6. Lift up the air cleaner outlet duct at the resonator tab in order to separate the resonator from the stud on the intake manifold. 7. Remove the air cleaner outlet duct from the throttle body and MAF/IAT sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 3217 1. Install the air cleaner outlet duct to the throttle body and MAF/IAT sensor. Ensure that the resonator tab aligns with the stud on the intake manifold. 2. Push down on the air cleaner outlet duct resonator directly over the resonator tab in order to secure the resonator to the stud on the intake manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 3. Tighten the air cleaner outlet duct clamp (2) at the throttle body to 4 Nm(35 lb in). 4. Tighten the air cleaner outlet duct clamp (1) to 4 Nm(35 lb in) at the MAF/IAT sensor. 5. Install the radiator inlet hose clamp retainer to the outlet duct. 6. Install the PCV line (1) to the air cleaner outlet duct. 7. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief (CH-48027) Special Tools CH-48027 - Digital Pressure Gauge Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 3225 * The fuel pipe connections * The hose connections * The areas surrounding the connections Note: If relieving the fuel pressure for the fuel pressure gauge installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Ignition System Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires, Incorrect routing may cause cross firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for any of the following conditions: * Tearing * Piercing * Arcing * Carbon tracking * Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 3232 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 3233 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Ignition System Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3237 Spark Plug: Application and ID Ignition System Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3238 Spark Plug: Testing and Inspection Spark Plug Inspection * Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Powertrain Management/Ignition System/Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling, replace with a colder plug - Pre-ignition causing spark plug and/or engine damage , replace with a hotter plug * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. * Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3239 * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection * Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak ignition coils * Worn ignition wires * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3240 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Brush or using compressed air, blow away any dirt from around the spark plug. 3. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3241 1. Inspect the spark plug gap. Adjust the gap as needed. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). 2. Hand start the spark plug in the corresponding cylinder. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the spark plug to 15 Nm (11 lb ft). 4. Install the spark plug wire to the spark plug. 5. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3245 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gauge at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts - First Pass............................................................................................................. ...........................................................15 Nm (11 lb ft.) Water Pump Bolts - Final Pass....................... ................................................................................................................................................30 Nm (22 lb ft.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3249 Water Pump: Service and Repair Water Pump Replacement (V8) Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair). 3. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 4. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting. 5. Reposition the radiator inlet hose clamp (3) at the water pump. 6. Remove the radiator inlet hose from the water pump. 7. Reposition the radiator inlet hose and vent inlet hose out of the way. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3250 8. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory). 9. Reposition the radiator outlet hose clamp at the water pump. 10. Remove the radiator outlet hose from the water pump. 11. Reposition the outlet hose out of the way. 12. Reposition the radiator surge tank outlet hose clamp at the water pump (1). 13. Remove the radiator surge tank outlet hose (2) from the water pump. 14. Reposition the outlet hose out of the way. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3251 15. Reposition the heater inlet hose clamp (1) at the water pump. 16. Remove the heater inlet hose (2) from the water pump. 17. Reposition the inlet hose out of the way. 18. Remove the water pump bolts (301). 19. Remove the water pump (300) and gaskets (309). Discard the gaskets. Installation Procedure Caution: DO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed. The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the passages of the cooling system or the engine components. Restricted coolant flow may cause engine overheating and/or damage to the cooling system or the engine components/assembly. Note: All gaskets surfaces are to be free of oil or other foreign material during assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3252 1. Inspect the drained coolant for sand or other debris, flush the system as needed. Refer to Flushing (See: Cooling System/Service and Repair/Flushing). 2. Inspect and clear the radiator vent hose fitting, if necessary. There is a small 2.0 mm (0.080 in) orifice (vent hose fitting) in the neck of the radiator where the coolant vent hose from the engine attaches to the radiator. 3. Position the water pump (300) and NEW gaskets (306) to the engine block. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the water pump bolts (301). 1. Tighten the bolts a first pass to 15 Nm (11 lb ft). 2. Tighten the bolts a final pass to 30 Nm (22 lb ft). 5. Position and install the heater inlet hose (2) to the water pump. 6. Position the heater inlet hose clamp (1) at the water pump. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3253 7. Position and install the radiator surge tank outlet hose (2) to the water pump. 8. Position the radiator surge tank outlet hose clamp at the water pump (1). 9. Position and install the radiator outlet hose to the water pump. 10. Position the radiator outlet hose clamp at the water pump. 11. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3254 12. Position the radiator inlet hose and vent inlet hose to the correct position. 13. Install the radiator inlet hose to the water pump. 14. Position the radiator inlet hose clamp (3) at the water pump. 15. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 16. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 17. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair). 18. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM 1500 Series ........................................................................................................ .............................................................................. 16.8 quarts (15.9 liters) 2500, 3500 Series .......... .............................................................................................................................................................. .... 16.4 quarts (15.5 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 3260 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in the vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in the vehicle for five years or 240 000 km (150,000 miles), whichever occurs first. The following explains the cooling system and how to check and add coolant when it is low. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. If using this mixture, nothing else needs to be added. This mixture: Gives freezing protection down to -34°F (-37°C). Gives boiling protection up to 265°F (129°C). Protects against rust and corrosion. Will not damage aluminum parts. Helps keep the proper engine temperature. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) Coolant Line/Hose: Service and Repair Engine Coolant Air Bleed Pipe Replacement (without AFM) Engine Coolant Air Bleed Pipe Replacement (without AFM) Removal Procedure 1. If replacing the rear coolant air bleed covers, remove the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine/Intake Manifold/Service and Repair). Otherwise proceed to the next step. 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 3. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 4. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 5. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 3265 6. Remove the coolant air bleed pipe bolts (309) (intake manifold shown removed for clarity). 7. Remove the coolant air bleed pipe (307) and seals (308). 8. Remove the coolant air bleed cover bolts (312), if required. 9. Remove the coolant air bleed covers (313) and seals (308), if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 3266 10. Remove the seals (308) from the coolant air bleed pipe and/or covers. 11. Discard the seals. Installation Procedure Note: Position the O-ring seal (308) onto the nipple portion of the pipe. 1. Install the seals onto the coolant air bleed pipe and/or covers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 3267 2. Install the coolant air bleed pipe (307) and seals (308) onto the cylinder heads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the coolant air bleed pipe bolts (309). Tighten the bolts to 12 Nm (106 lb in). 4. Install the coolant air bleed covers (313) and seals (308), if required. 5. Install the coolant air bleed cover bolts (312), if required. Tighten the bolts to 12 Nm (106 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 3268 6. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 7. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 10. If the rear coolant air bleed covers were replaced, install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 3269 Coolant Line/Hose: Service and Repair Engine Coolant Air Bleed Pipe Replacement (with AFM) Engine Coolant Air Bleed Pipe Replacement (with AFM) Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 3. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 4. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting. 5. Remove the coolant air bleed pipe bolts (309) (intake manifold shown removed for clarity). 6. Remove the coolant air bleed pipe (307) and seals (308). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 3270 7. Remove the coolant air bleed cover bolts (312), if required. 8. Discard the seals. Installation Procedure Note: Position the O-ring seal (308) onto the nipple portion of the pipe. 1. Install the seals onto the coolant air bleed pipe and/or covers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 3271 2. Install the coolant air bleed pipe (307) and seals (308) onto the cylinder heads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the coolant air bleed pipe bolts (309). Tighten the bolts to 12 Nm (106 lb in). 4. Install the coolant air bleed covers (313) and seals (308), if required. 5. Install the coolant air bleed cover bolts (312), if required. Tighten the bolts to 12 Nm (106 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Engine Coolant Air Bleed Pipe Replacement (without AFM) > Page 3272 6. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 7. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 10. If the rear coolant air bleed covers were replaced, install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Radiator Surge Tank Replacement Coolant Reservoir: Service and Repair Radiator Surge Tank Replacement Radiator Surge Tank Replacement (Non-HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Radiator Surge Tank Replacement > Page 3277 Coolant Reservoir: Service and Repair Radiator Surge Tank Inlet Hose/Pipe Replacement Radiator Surge Tank Inlet Hose/Pipe Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 2. Reposition the surge tank inlet hose clamp from the radiator. 3. Remove the surge tank inlet hose from the radiator. 4. Reposition the surge tank inlet hose clamp at the surge tank. 5. Remove the surge tank inlet hose (1) from the surge tank. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Radiator Surge Tank Replacement > Page 3278 1. Install the surge tank inlet hose (1) to the surge tank. 2. Position the surge tank inlet hose clamp to the surge tank. 3. Install the surge tank inlet hose to the radiator. 4. Position the surge tank inlet hose clamp to the radiator. 5. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Radiator Surge Tank Replacement > Page 3279 Coolant Reservoir: Service and Repair Radiator Vent Inlet Hose Replacement Radiator Vent Inlet Hose Replacement (Non-HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams Radiator Cooling Fan Motor: Diagrams Component Connector End Views Engine Cooling Fan - Left (Gas except LY6) Engine Cooling Fan - Right (Gas except LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 3284 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 3285 Radiator Cooling Fan Motor: Service and Repair Engine Coolant Fan Motor Replacement (Non-HP2) Removal Procedure 1. Remove the cooling blade(s). Refer to Engine Coolant Fan Replacement (Non-HP2) (See: Service and Repair). 2. Remove the cooling fan motor bolts. 3. Remove the cooling fan motor(s). Installation Procedure 1. Install the cooling fan motor(s). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 3286 2. Install the cooling fan motor bolts. Tighten the bolts to 10 Nm (89 lb in). 3. Install the cooling fan blades. Refer to Engine Coolant Fan Replacement (Non-HP2) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3290 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3291 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3292 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3293 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3294 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3295 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3296 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection Fan Clutch: Testing and Inspection Fan Clutch Diagnosis Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Page 3300 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3310 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3311 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3312 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3313 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3319 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3320 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3321 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3322 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Check Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 3328 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 3329 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 3330 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 3331 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 3337 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 3338 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 3339 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 3340 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3341 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3342 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor. 3. Remove the ECT sensor. Installation Procedure Caution: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3343 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ECT sensor and tighten to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor. 4. Refill the cooling. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement Fan Shroud: Service and Repair Cooling Fan and Shroud Replacement Cooling Fan and Shroud Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair) 2. Remove air inlet duct. 3. Disconnect upper radiator hose from radiator. 4. Disengage the radiator inlet hose clip (2) at the fan shroud. 5. If necessary, reposition the surge tank inlet hose clamp at the radiator. 6. If necessary, remove the surge tank inlet hose from the radiator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3348 7. Disconnect the electrical connectors from the cooling fans. 8. Remove the clip attaching the wiring harness to the shroud. 9. Remove transmission cooler lines bolts from fan shroud. 10. If necessary, open the engine oil cooler line clip and remove the cooler lines from the clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3349 11. Remove the cooling fan shroud bolts. 12. Remove the cooling fan and shroud. Installation Procedure Note: Insert the 3 lower tabs into the radiator support flange. Keeping the shroud parallel to the radiator will ensure the correct installation of the lower tabs. 1. Install the cooling fan and shroud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the cooling fan shroud bolts. Tighten the bolts to 9 Nm (80 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3350 3. If equipped, install the cooler lines to the clip and close the clip. 4. Connect the electrical connectors to the cooling fans. 5. Install the clip attaching the wiring harness to the shroud. 6. Install the transmission cooling line bolts to fan shroud. Tighten the bolts to 4 Nm (35 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3351 7. If necessary, install the surge tank inlet hose to the radiator. 8. If necessary, reposition the surge tank inlet hose clamp at the radiator. 9. Engage the radiator inlet hose clip (2) at the fan shroud. 10. Connect upper radiator hose from radiator. 11. Install air inlet duct. 12. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3352 Fan Shroud: Service and Repair Engine Coolant Fan Upper Shroud Replacement (Mechanical) Engine Coolant Fan Upper Shroud Replacement (Mechanical) Removal Procedure 1. Loosen the air cleaner outlet duct clamps from the throttle body. 2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor (2). 3. Remove the air cleaner outlet duct. 4. If equipped remove the throttle body heater hose retainer from the fan shroud. 5. If equipped remove the inlet radiator hose retainer from the fan shroud. 6. Remove the fan shroud retainers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3353 7. Remove the fan shroud bolts 8. Remove the upper fan shroud. Installation Procedure 1. Install the upper fan shroud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fan shroud bolts. Tighten the bolts to 9 Nm (80 lb in). 3. Install the fan shroud retainers. 4. If equipped install the inlet radiator hose retainer to the fan shroud 5. If equipped install the throttle body heater hose retainer to the fan shroud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3354 6. Install the air cleaner outlet duct. 7. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten the clamp to 4 Nm (35 lb in). 8. Tighten the air cleaner outlet duct clamp at the mass airflow sensor (2). Tighten the clamp to 4 Nm (35 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3355 Fan Shroud: Service and Repair Engine Coolant Fan Lower Shroud Replacement (Mechanical) Engine Coolant Fan Lower Shroud Replacement (Mechanical) Removal Procedure 1. Remove the radiator. Refer to Radiator Replacement (LMM) (See: Radiator/Service and Repair/Removal and Replacement)Radiator Replacement (4.3L, 4.8L, 5.3L, and 6.0L) (See: Radiator/Service and Repair/Removal and Replacement). 2. Disengage the two clips from the radiator. 3. If equipped with engine oil cooler , remove the oil cooler hose clip from the lower fan shroud. 4. Remove the shroud from the vehicle. Installation Procedure 1. Install the lower fan shroud and ensure it is centered over lower radiator support. 2. Engage the two clips from the radiator. 3. If equipped with the engine oil cooler , Install the oil cooler hose clip to the lower fan shroud. 4. Install the radiator. Refer to Radiator Replacement (LMM) (See: Radiator/Service and Repair/Removal and Replacement)Radiator Replacement (4.3L, 4.8L, 5.3L, and 6.0L) (See: Radiator/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Cover Replacement Heater Core: Service and Repair Heater Core Cover Replacement Heater Core Cover Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Cover Replacement > Page 3360 Heater Core: Service and Repair Heater Core Replacement Heater Core Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) Heater Hose: Service and Repair Heater Inlet Hose Replacement (Non-HP2) Heater Inlet Hose Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. Quick Connect Fittings 5. Pull the connection apart. 6. Remove the inlet heater hose from the water pump. 7. Remove the inlet heater hose. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 3365 Installation Procedure 1. Install the inlet heater hose. 2. Install the inlet heater hose to the water pump. 3. Connect the heater hose to the heater core. Important: Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hoses to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 3366 Heater Hose: Service and Repair Heater Outlet Hose Replacement (Non-HP2) Heater Outlet Hose Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. Quick Connect Fittings 5. Pull the connection apart. 6. Remove the outlet heater hose from the water pump. 7. Reposition the outlet heater hose clamp at the surge tank. 8. Remove the outlet heater hose from the surge tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 3367 9. Remove the outlet heater hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Important: Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Pull the heater outlet hose to ensure the connection. 7. Install the heater and surge tank hoses to the mounting clip. 8. Install the air intake tube. 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures Radiator: Procedures Radiator Cleaning Warning NEVER spray water on a hot heat exchanger. The resulting steam could cause personal injury. Caution: The heat exchanger fins are necessary for good heat transfer. Do not brush the fins. This may cause damage to the fins, reducing heat transfer. Note: Remove bugs, leaves, dirt and other debris by blowing compressed air through the engine side of the radiator. * Some conditions may require the use of warm water and a mild detergent. * Clean the A/C condenser fins. * Clean between the A/C condenser and radiator. * Clean the radiator cooling fins. * Straighten any damaged cooling fins. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 3372 Radiator: Removal and Replacement Radiator Replacement Radiator Replacement (4.3L, 4.8L, 5.3L, and 6.0L) Removal Procedure 1. Remove the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement (Non-HP2) (See: Radiator Cooling Fan/Service and Repair). 2. Remove the radiator outlet hose for the 4.3L engine, or the 4.8L, 5.3L and 6.0L engines. Refer to Radiator Outlet Hose Replacement (Diesel) ( See: Radiator Hose)Radiator Outlet Hose Replacement (Non-HP2) (See: Radiator Hose). 3. Disconnect the engine oil cooler lines from the radiator, If Equipped. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement ( See: Engine/Engine Lubrication/Oil Cooler/Service and Repair/Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement). 4. Disconnect the transmission oil cooler lines from the radiator, If Equipped. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 5. Remove the radiator bolts. 6. Remove the radiator. Installation Procedure 1. Install the radiator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the radiator bolts. Tighten the bolts to 25 Nm (18 lb ft). 3. Connect the transmission oil cooler lines to the radiator, If Equipped. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Connect the engine oil cooler lines to the radiator, If Equipped. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement (See: Engine/Engine Lubrication/Oil Cooler/Service and Repair/Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement). 5. Install the radiator outlet hose for the 4.3L engine, or the 4.8L, 5.3L and 6.0L engines. Refer to Radiator Outlet Hose Replacement (Diesel) (See: Radiator Hose)Radiator Outlet Hose Replacement (Non-HP2) (See: Radiator Hose). 6. Install the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement (Non-HP2) (See: Radiator Cooling Fan/Service and Repair). Radiator Air Upper Baffle and Deflector Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 3373 Radiator Air Upper Baffle and Deflector Replacement Removal Procedure 1. Remove the radiator air upper baffle retainers (Qty 8). 2. Remove the radiator air upper baffle. Installation Procedure 1. Install the radiator air upper baffle. 2. Install the radiator air upper baffle retainers (Qty 8). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection Radiator Cap: Testing and Inspection Pressure Cap Testing Special Tools * J 24460-01 Cooling System Pressure Tester * J 42401 Radiator Cap/Surge Tank Test Adapter Pressure Cap Testing Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. 1. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water. Note: Lubricate J-42401 and pressure cap o-rings with coolant and press cap to seat o-ring on J-42401 before turning to engage threads. 3. Use the J 24460-01 (1) with J 42401 (2) in order to test the pressure cap. 4. Test the pressure cap for the following conditions: * Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. * Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss. 5. Replace the pressure cap under the following conditions: * The pressure cap does not release pressure which exceeds the rated pressure of the cap. * The pressure cap does not hold the rated pressure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement Radiator Hose: Service and Repair Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement (Non-HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 3381 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement (Non-HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 3382 Radiator Hose: Service and Repair Radiator Hose Quick Connect Fitting Radiator Hose Quick Connect Fitting Removal Procedure 1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 2. Rotate the retaining ring (3) around the quick connector until the retaining ring is out of position and can be completely removed. 3. Remove the radiator outlet hose (2) from the quick connector fitting at the radiator (1). Installation Procedure Note: Do not install the retaining ring (3) onto the fitting by pushing the retaining ring down over the fitting. 1. Hook one of the open ends of the retaining ring (3) in one of the slots in the quick connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 3383 2. Rotate the retaining ring (3) around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 3. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 4. Install the radiator outlet hose (2) onto the radiator quick connector fitting until a click is heard or felt. Pull back on the radiator outlet hose (2) to ensure a proper connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3388 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3389 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3390 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3391 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3392 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3393 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3394 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3405 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3406 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3407 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3408 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3414 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3415 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3416 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3417 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3418 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3419 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor. 3. Remove the ECT sensor. Installation Procedure Caution: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3420 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ECT sensor and tighten to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor. 4. Refill the cooling. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications The thermostat should begin to open at ........................................................................................................................................................... 87°C (188°F) The thermostat should be fully open at ............................................................................................................................................................ 97°C (206°F) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3424 Thermostat: Service and Repair Engine Coolant Thermostat Replacement (Gas) Removal Procedure 1. Remove the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement (LFA,LH6, LMG,LY2, LY5,LY6) (See: Thermostat Housing/Service and Repair). 2. Remove the thermostat. Installation Procedure 1. Install the thermostat. 2. Install the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement (LFA,LH6, LMG,LY2, LY5,LY6) (See: Thermostat Housing/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair Thermostat Housing: Service and Repair Engine Coolant Thermostat Housing Replacement (LFA,LH6, LMG,LY2, LY5,LY6) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 3. Reposition the radiator outlet hose clamp at the water pump inlet. 4. Remove the radiator outlet hose from the water pump inlet. 5. Remove the water pump inlet bolts (1). 6. Remove the water pump inlet from the water pump. 7. Remove and discard the water pump inlet seal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 3428 Installation Procedure 1. Install a NEW water pump inlet seal to the water pump inlet. 2. Position the water pump inlet to the water pump. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the water pump inlet bolts (1) and tighten to 15 Nm (11 lb ft). 4. Install the radiator outlet hose to the water pump inlet. 5. Position the radiator outlet hose clamp at the water pump inlet. 6. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 7. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts - First Pass............................................................................................................. ...........................................................15 Nm (11 lb ft.) Water Pump Bolts - Final Pass....................... ................................................................................................................................................30 Nm (22 lb ft.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3432 Water Pump: Service and Repair Water Pump Replacement (V8) Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 3. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 4. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting. 5. Reposition the radiator inlet hose clamp (3) at the water pump. 6. Remove the radiator inlet hose from the water pump. 7. Reposition the radiator inlet hose and vent inlet hose out of the way. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3433 8. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory). 9. Reposition the radiator outlet hose clamp at the water pump. 10. Remove the radiator outlet hose from the water pump. 11. Reposition the outlet hose out of the way. 12. Reposition the radiator surge tank outlet hose clamp at the water pump (1). 13. Remove the radiator surge tank outlet hose (2) from the water pump. 14. Reposition the outlet hose out of the way. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3434 15. Reposition the heater inlet hose clamp (1) at the water pump. 16. Remove the heater inlet hose (2) from the water pump. 17. Reposition the inlet hose out of the way. 18. Remove the water pump bolts (301). 19. Remove the water pump (300) and gaskets (309). Discard the gaskets. Installation Procedure Caution: DO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed. The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the passages of the cooling system or the engine components. Restricted coolant flow may cause engine overheating and/or damage to the cooling system or the engine components/assembly. Note: All gaskets surfaces are to be free of oil or other foreign material during assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3435 1. Inspect the drained coolant for sand or other debris, flush the system as needed. Refer to Flushing (See: Service and Repair/Flushing). 2. Inspect and clear the radiator vent hose fitting, if necessary. There is a small 2.0 mm (0.080 in) orifice (vent hose fitting) in the neck of the radiator where the coolant vent hose from the engine attaches to the radiator. 3. Position the water pump (300) and NEW gaskets (306) to the engine block. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the water pump bolts (301). 1. Tighten the bolts a first pass to 15 Nm (11 lb ft). 2. Tighten the bolts a final pass to 30 Nm (22 lb ft). 5. Position and install the heater inlet hose (2) to the water pump. 6. Position the heater inlet hose clamp (1) at the water pump. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3436 7. Position and install the radiator surge tank outlet hose (2) to the water pump. 8. Position the radiator surge tank outlet hose clamp at the water pump (1). 9. Position and install the radiator outlet hose to the water pump. 10. Position the radiator outlet hose clamp at the water pump. 11. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3437 12. Position the radiator inlet hose and vent inlet hose to the correct position. 13. Install the radiator inlet hose to the water pump. 14. Position the radiator inlet hose clamp (3) at the water pump. 15. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 16. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 17. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 18. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service Precautions Catalytic Converter: Service Precautions Three-Way Catalytic Converter Damage Caution Caution: In order to avoid damaging the replacement three-way catalytic converter, correct the engine misfire or mechanical fault before replacing the three-way catalytic converter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) Catalytic Converter: Service and Repair Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) > Page 3444 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) > Page 3445 Catalytic Converter: Service and Repair Catalytic Converter Replacement (LFA with Exhaust Clamp) Catalytic Converter Replacement (LFA with Exhaust Clamp) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) > Page 3446 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) > Page 3447 Catalytic Converter: Service and Repair Catalytic Converter Replacement Catalytic Converter Replacement (LY6 with Exhaust Flange) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) > Page 3448 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) > Page 3449 Catalytic Converter: Service and Repair Catalytic Converter Replacement - Left Side (Cab Chassis) Catalytic Converter Replacement - Left Side (Cab Chassis) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Bolts - First Pass...................................................................................................... .........................................................15 Nm (11 lb ft.) Exhaust Manifold Bolts - Final Pass................. .............................................................................................................................................20 Nm (15 lb ft.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left SIde Exhaust Manifold Replacement - Left Side (V8) Special Tools J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Install the J 42640 into the steering column lower access hole. 2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 3. Fully raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3455 4. Remove the catalytic converter to exhaust manifold nuts. (1500 series shown, 2500 series similar). 5. Lower the vehicle part way in order to work through the wheel opening. 6. Remove the spark plug wires from the spark plugs. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 7. Remove the spark plug wires from the ignition coils. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3456 8. Mark the relationship of the upper intermediate steering shaft to the steering column. 9. Remove the steering shaft coupling bolt (2) and nut (1) from the upper intermediate steering shaft. 10. Separate the upper intermediate steering shaft (3) from the steering column, position both shafts out of the way. 11. Remove the exhaust manifold bolts, and exhaust manifold. 12. Remove and discard the exhaust manifold gasket. 13. Remove and discard the catalytic converter seal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3457 14. If replacing the exhaust manifold, remove the exhaust manifold heat shield bolts, and shield from the exhaust manifold. Installation Procedure Note: * Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostic (OBD) II system performance. * The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. * Do not apply sealant to the first 3 threads of the bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. If the exhaust manifold was replaced, position and install the exhaust manifold heat shield, and bolts to the exhaust manifold. Tighten the bolts to 9 Nm (80 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3458 2. Clean the threads of the exhaust manifold bolts. 3. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts. 4. Install a NEW catalytic converter seal to the catalytic converter. 5. Position the NEW exhaust manifold gasket and exhaust manifold to the cylinder head. 6. Ensure that the exhaust manifold is seated to the catalytic converter. 7. Install the exhaust manifold bolts. 1. Tighten the bolts a first pass to 15 Nm (11 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 2. Tighten the bolts a final pass to 20 Nm (15 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 8. Using a flat punch, bend the gasket tab at the rear of the gasket around the cylinder head edge. 9. Position and align the marks on the upper intermediate steering shaft and the steering column. 10. Install the upper intermediate steering shaft (3) to the steering column. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3459 11. Install the steering shaft coupling bolt (2) and nut (1) to the upper intermediate steering shaft. Tighten the bolt/nut to 50 Nm (37 lb ft). 12. Install the spark plug wires to the spark plugs. 13. Install the spark plug wires to the ignition coils. 14. Inspect the spark plug wires for proper installation. 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. 15. Fully raise and support the vehicle. 16. Install the catalytic converter to exhaust manifold nuts. (1500 series shown, 2500 series similar). Tighten the nuts to 50 Nm (37 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3460 17. Partially lower the vehicle. 18. Install the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 19. Remove the J 42640 from the steering column lower access hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3461 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Side Exhaust Manifold Replacement - Right Side (V8) Removal Procedure 1. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement Bank 2 Sensor 1 (2500 Series - Cab/Chassis) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair)Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair)Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair). 2. Fully raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the catalytic converter to exhaust manifold nuts, 1500 series shown, 2500 series similar. 4. Remove the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3462 Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 5. Remove the spark plug wires (1) from the spark plugs. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 6. Remove the spark plug wires from the ignition coils. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. 7. Remove the oil level indicator tube bolt (419). 8. Remove the oil level indicator tube (420) from the engine block. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3463 9. Remove the exhaust manifold bolts and exhaust manifold. 10. Remove and discard the exhaust manifold gasket. 11. Remove and discard the exhaust manifold seal. 12. If replacing the exhaust manifold, remove the exhaust manifold heat shield bolts, and shield from the exhaust manifold. Installation Procedure Note: * Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance. * The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. * Do not apply sealant to the first 3 threads of the bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. If the exhaust manifold was replaced, position and install the exhaust manifold heat shield, and bolts to the exhaust manifold. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3464 Tighten the bolts to 9 Nm (80 lb in). 2. Clean the threads of the exhaust manifold bolts. 3. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts. 4. Install a NEW catalytic converter seal to the exhaust manifold. 5. Position the NEW exhaust manifold gasket and exhaust manifold to the cylinder head. 6. Ensure that the catalytic converter seal is seated to the catalytic converter. 7. Install the exhaust manifold bolts. 1. Tighten the bolts a first pass to 15 Nm (11 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 2. Tighten the bolts a final pass to 20 Nm (15 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 8. Using a flat punch, bend the gasket tab at the rear of the gasket around the cylinder head edge. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3465 Note: The O-ring seal may be reused if not cut or damaged. 9. Inspect the O-ring seal (421) for cuts or damage, replace as necessary. 10. Lubricate the O-ring seal (421) with clean engine oil. 11. Install the oil level indicator tube (420) to the engine block. 12. Install the oil level indicator tube bolt (419). Tighten the bolt 25 Nm (18 lb ft). 13. Install the spark plug wires (1) to the spark plugs. 14. Install the spark plug wires to the ignition coils. 15. Inspect the spark plug wires for proper installation. 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3466 16. Install the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 17. Fully raise and support the vehicle. 18. Install the catalytic converter to exhaust manifold nuts, 1500 series shown, 2500 series similar. Tighten the nuts to 50 Nm (37 lb ft). Partially lower the vehicle in order to work through the wheel opening. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair)Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair)Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Exhaust Clamp > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-05-003A > Feb > 11 > Exhaust System Exhaust Leak/Rattle/Rumble/Noises Exhaust Clamp: Customer Interest Exhaust System - Exhaust Leak/Rattle/Rumble/Noises TECHNICAL Bulletin No.: 10-06-05-003A Date: February 04, 2011 Subject: Exhaust Leak, Rattle, Rumble and/or Noise (Install New Clamp and Align Correctly) Models: 2009-2011 Cadillac Escalade Hybrid 2009-2011 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, Tahoe Hybrid 2009-2011 GMC Sierra 1500, Yukon, Yukon Hybrid, Yukon XL Equipped with 4.3L, 4.8L, 5.3L or 6.0L Engine 2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2011 Chevrolet Avalanche, Silverado, Suburban 2011 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL, Yukon Denali XL All Equipped with 6.2L Engine Supercede: This bulletin is being revised to add Parts Information. Please discard Corporate Bulletin Number 10-06-05-003 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an exhaust leak or noise. The noise may be described as a rattle or rumble. Cause This condition may be caused by an unseated pipe to pipe mid-joint connection as shown below. Correction Note Ensure that the pipe flares remain fully seated to each other while tightening the clamp. 1. Remove and discard the exhaust band (Norma) clamp. 2. Install and position a new exhaust band (Norma) clamp to the pipe joint. 3. Firmly push and maintain the pipes together while tightening the exhaust band (Norma) clamp bolt. Tighten Tighten the clamp bolt to 28 Nm (21 lb ft). Note After the clamp is installed, it does not need to be perpendicular to the pipe. It is acceptable to have a pipe to pipe or clamp angle. 4. Confirm that the clamp edges (both sides and all the way around the clamp) are fully seated on the pipe. 5. Run the engine and inspect the clamp joint to ensure there are no leaks and to ensure that the condition is corrected. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Exhaust Clamp > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-05-003A > Feb > 11 > Exhaust System Exhaust Leak/Rattle/Rumble/Noises > Page 3476 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Exhaust Clamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-05-003A > Feb > 11 > Exhaust System - Exhaust Leak/Rattle/Rumble/Noises Exhaust Clamp: All Technical Service Bulletins Exhaust System - Exhaust Leak/Rattle/Rumble/Noises TECHNICAL Bulletin No.: 10-06-05-003A Date: February 04, 2011 Subject: Exhaust Leak, Rattle, Rumble and/or Noise (Install New Clamp and Align Correctly) Models: 2009-2011 Cadillac Escalade Hybrid 2009-2011 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, Tahoe Hybrid 2009-2011 GMC Sierra 1500, Yukon, Yukon Hybrid, Yukon XL Equipped with 4.3L, 4.8L, 5.3L or 6.0L Engine 2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2011 Chevrolet Avalanche, Silverado, Suburban 2011 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL, Yukon Denali XL All Equipped with 6.2L Engine Supercede: This bulletin is being revised to add Parts Information. Please discard Corporate Bulletin Number 10-06-05-003 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an exhaust leak or noise. The noise may be described as a rattle or rumble. Cause This condition may be caused by an unseated pipe to pipe mid-joint connection as shown below. Correction Note Ensure that the pipe flares remain fully seated to each other while tightening the clamp. 1. Remove and discard the exhaust band (Norma) clamp. 2. Install and position a new exhaust band (Norma) clamp to the pipe joint. 3. Firmly push and maintain the pipes together while tightening the exhaust band (Norma) clamp bolt. Tighten Tighten the clamp bolt to 28 Nm (21 lb ft). Note After the clamp is installed, it does not need to be perpendicular to the pipe. It is acceptable to have a pipe to pipe or clamp angle. 4. Confirm that the clamp edges (both sides and all the way around the clamp) are fully seated on the pipe. 5. Run the engine and inspect the clamp joint to ensure there are no leaks and to ensure that the condition is corrected. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Exhaust Clamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-05-003A > Feb > 11 > Exhaust System - Exhaust Leak/Rattle/Rumble/Noises > Page 3482 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Exhaust Clamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exhaust Clamp: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Exhaust Clamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exhaust Clamp: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 3488 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Exhaust Clamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exhaust Clamp: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 3494 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation Exhaust Pipe/Muffler Hanger: Customer Interest Exhaust - Muffler Heat Shield Buzz During Operation TECHNICAL Bulletin No.: 07-06-05-001I Date: March 22, 2011 Subject: V8 Engines - Muffler Heat Shield Buzz During Vehicle Operation (Perform Repair as Outlined) or Exhaust Pinging/Popping/Snapping Noise During Cool Down, at Idle, or After Vehicle is Shut Off (Normal Characteristic - No Repair Required) Models: 2007-2011 Cadillac Escalade, Escalade Hybrid, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Tahoe Hybrid 2007-2011 GMC Sierra, Sierra Denali, Yukon, Yukon Hybrid, Yukon XL, Yukon Denali, Yukon Denali XL Equipped with the following V8 Engines: - 4.8L (RPO LY2, L20) - 5.3L (RPOs LC9, LH6, LMG, LY5) - 6.0L (RPOs LFA, LY6, LZ1, L96) - 6.2L (RPOs L9H, L92, L94) Please Refer to GWM/IVH Supercede: This bulletin is being revised to update the Condition, Cause and Correction information. Please discard Corporate Bulletin Number 07-06-05-001H (Section 06 Engine/Propulsion System). Condition 1 Some customers may comment on a pinging/popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause 1 Exhaust Pinging/Popping/Snapping As the exhaust system cools, the muffler shell and muffler internals contract at different rates. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. Correction 1 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Exhaust Pinging/Popping/Snapping Noise (Normal) This condition is normal to the muffler design and does not indicate poor quality or part failure. No repairs are necessary for this condition. Replacing the muffler heat shield straps will NOT eliminate this noise. A new muffler may sound quiet for this condition, but as it ages may again produce this same condition. Condition 2 Some customers may also comment on a buzz noise coming from the muffler during vehicle operation. Cause 2 Muffler Heat Shield Buzz If the muffler heat shield straps are loose, the heat shield may be free to buzz during vehicle operation. Correction 2 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Muffler Heat Shield Buzz (Perform Repair) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation > Page 3503 Confirm the origin of the buzz by shimming (use metal shims) the straps tight and rerunning the vehicle. If the buzz concern is gone, then it is caused by the loose shield. Using the following procedure, install new straps to secure the heat shield to the muffler. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Mark the position of the heat shield (1) and straps (2) on the muffler shell. 3. Cut and remove the heat shield straps using tin snips along the muffler shell seam (1), and remove the shield from the muffler. 4. Position the heat shield to the muffler and install new heat shield straps on the muffler shell in the positions marked prior to removal. Important Do Not position the strap screw heads directly across from the propeller shaft. Ensure the strap heads are positioned below the midpoint of the muffler. 5. Position the strap screw heads (1) on the inboard side of the muffler. Ensure that the strap screw heads (1) are below the midpoint of the muffler. Tighten Tighten the straps to 4 Nm (35‹›lb‹›in). 6. Cut off the excess strap material and ensure that the ends (2) are flat against the muffler. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation > Page 3504 Warranty Information For vehicles with Exhaust Pinging/Popping/Snapping Noise, NO repairs are necessary as it is a normal condition. For vehicles repaired for a muffler buzz, use the labor operation. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 10-06-05-003A > Feb > 11 > Exhaust System - Exhaust Leak/Rattle/Rumble/Noises Exhaust Pipe/Muffler Hanger: Customer Interest Exhaust System - Exhaust Leak/Rattle/Rumble/Noises TECHNICAL Bulletin No.: 10-06-05-003A Date: February 04, 2011 Subject: Exhaust Leak, Rattle, Rumble and/or Noise (Install New Clamp and Align Correctly) Models: 2009-2011 Cadillac Escalade Hybrid 2009-2011 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, Tahoe Hybrid 2009-2011 GMC Sierra 1500, Yukon, Yukon Hybrid, Yukon XL Equipped with 4.3L, 4.8L, 5.3L or 6.0L Engine 2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2011 Chevrolet Avalanche, Silverado, Suburban 2011 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL, Yukon Denali XL All Equipped with 6.2L Engine Supercede: This bulletin is being revised to add Parts Information. Please discard Corporate Bulletin Number 10-06-05-003 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an exhaust leak or noise. The noise may be described as a rattle or rumble. Cause This condition may be caused by an unseated pipe to pipe mid-joint connection as shown below. Correction Note Ensure that the pipe flares remain fully seated to each other while tightening the clamp. 1. Remove and discard the exhaust band (Norma) clamp. 2. Install and position a new exhaust band (Norma) clamp to the pipe joint. 3. Firmly push and maintain the pipes together while tightening the exhaust band (Norma) clamp bolt. Tighten Tighten the clamp bolt to 28 Nm (21 lb ft). Note After the clamp is installed, it does not need to be perpendicular to the pipe. It is acceptable to have a pipe to pipe or clamp angle. 4. Confirm that the clamp edges (both sides and all the way around the clamp) are fully seated on the pipe. 5. Run the engine and inspect the clamp joint to ensure there are no leaks and to ensure that the condition is corrected. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 10-06-05-003A > Feb > 11 > Exhaust System - Exhaust Leak/Rattle/Rumble/Noises > Page 3509 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Exhaust - Muffler Heat Shield Buzz During Operation TECHNICAL Bulletin No.: 07-06-05-001I Date: March 22, 2011 Subject: V8 Engines - Muffler Heat Shield Buzz During Vehicle Operation (Perform Repair as Outlined) or Exhaust Pinging/Popping/Snapping Noise During Cool Down, at Idle, or After Vehicle is Shut Off (Normal Characteristic - No Repair Required) Models: 2007-2011 Cadillac Escalade, Escalade Hybrid, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Tahoe Hybrid 2007-2011 GMC Sierra, Sierra Denali, Yukon, Yukon Hybrid, Yukon XL, Yukon Denali, Yukon Denali XL Equipped with the following V8 Engines: - 4.8L (RPO LY2, L20) - 5.3L (RPOs LC9, LH6, LMG, LY5) - 6.0L (RPOs LFA, LY6, LZ1, L96) - 6.2L (RPOs L9H, L92, L94) Please Refer to GWM/IVH Supercede: This bulletin is being revised to update the Condition, Cause and Correction information. Please discard Corporate Bulletin Number 07-06-05-001H (Section 06 Engine/Propulsion System). Condition 1 Some customers may comment on a pinging/popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause 1 Exhaust Pinging/Popping/Snapping As the exhaust system cools, the muffler shell and muffler internals contract at different rates. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. Correction 1 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Exhaust Pinging/Popping/Snapping Noise (Normal) This condition is normal to the muffler design and does not indicate poor quality or part failure. No repairs are necessary for this condition. Replacing the muffler heat shield straps will NOT eliminate this noise. A new muffler may sound quiet for this condition, but as it ages may again produce this same condition. Condition 2 Some customers may also comment on a buzz noise coming from the muffler during vehicle operation. Cause 2 Muffler Heat Shield Buzz If the muffler heat shield straps are loose, the heat shield may be free to buzz during vehicle operation. Correction 2 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Muffler Heat Shield Buzz (Perform Repair) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation > Page 3515 Confirm the origin of the buzz by shimming (use metal shims) the straps tight and rerunning the vehicle. If the buzz concern is gone, then it is caused by the loose shield. Using the following procedure, install new straps to secure the heat shield to the muffler. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Mark the position of the heat shield (1) and straps (2) on the muffler shell. 3. Cut and remove the heat shield straps using tin snips along the muffler shell seam (1), and remove the shield from the muffler. 4. Position the heat shield to the muffler and install new heat shield straps on the muffler shell in the positions marked prior to removal. Important Do Not position the strap screw heads directly across from the propeller shaft. Ensure the strap heads are positioned below the midpoint of the muffler. 5. Position the strap screw heads (1) on the inboard side of the muffler. Ensure that the strap screw heads (1) are below the midpoint of the muffler. Tighten Tighten the straps to 4 Nm (35‹›lb‹›in). 6. Cut off the excess strap material and ensure that the ends (2) are flat against the muffler. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation > Page 3516 Warranty Information For vehicles with Exhaust Pinging/Popping/Snapping Noise, NO repairs are necessary as it is a normal condition. For vehicles repaired for a muffler buzz, use the labor operation. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 10-06-05-003A > Feb > 11 > Exhaust System - Exhaust Leak/Rattle/Rumble/Noises Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Exhaust System - Exhaust Leak/Rattle/Rumble/Noises TECHNICAL Bulletin No.: 10-06-05-003A Date: February 04, 2011 Subject: Exhaust Leak, Rattle, Rumble and/or Noise (Install New Clamp and Align Correctly) Models: 2009-2011 Cadillac Escalade Hybrid 2009-2011 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, Tahoe Hybrid 2009-2011 GMC Sierra 1500, Yukon, Yukon Hybrid, Yukon XL Equipped with 4.3L, 4.8L, 5.3L or 6.0L Engine 2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2011 Chevrolet Avalanche, Silverado, Suburban 2011 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL, Yukon Denali XL All Equipped with 6.2L Engine Supercede: This bulletin is being revised to add Parts Information. Please discard Corporate Bulletin Number 10-06-05-003 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an exhaust leak or noise. The noise may be described as a rattle or rumble. Cause This condition may be caused by an unseated pipe to pipe mid-joint connection as shown below. Correction Note Ensure that the pipe flares remain fully seated to each other while tightening the clamp. 1. Remove and discard the exhaust band (Norma) clamp. 2. Install and position a new exhaust band (Norma) clamp to the pipe joint. 3. Firmly push and maintain the pipes together while tightening the exhaust band (Norma) clamp bolt. Tighten Tighten the clamp bolt to 28 Nm (21 lb ft). Note After the clamp is installed, it does not need to be perpendicular to the pipe. It is acceptable to have a pipe to pipe or clamp angle. 4. Confirm that the clamp edges (both sides and all the way around the clamp) are fully seated on the pipe. 5. Run the engine and inspect the clamp joint to ensure there are no leaks and to ensure that the condition is corrected. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 10-06-05-003A > Feb > 11 > Exhaust System - Exhaust Leak/Rattle/Rumble/Noises > Page 3521 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Page 3522 Exhaust Pipe/Muffler Hanger: Service and Repair Exhaust Hanger Mounting Bracket Replacement (without L96/E63/ZW9) Removal Procedure 1. If equipped with a 6.0L engine, remove the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement (See: Exhaust Pipe/Service and Repair/Exhaust Manifold Pipe Replacement). 2. If equipped with a 6.0L engine, remove the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side (Cab Chassis) (See: Catalytic Converter/Service and Repair). 3. If equipped with a 6.6L engine, remove the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) ( See: Catalytic Converter/Service and Repair). 4. If equipped with a 4L80-E automatic transmission, regular production option (RPO) MT1, remove the exhaust pipe hanger bracket bolts and bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Page 3523 5. If equipped with a Allison(R) automatic transmission, RPO MW7, remove the exhaust pipe hanger bracket bolt/stud and bracket. 6. If equipped with a 6L90-E automatic transmission, RPO MYD, remove the exhaust pipe hanger bracket bolts and bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Page 3524 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. If equipped with a 6L90-E automatic transmission, RPO MYD, install the exhaust pipe hanger bracket and bolts and tighten to 25 Nm (18 lb ft). 2. If equipped with a Allison(R) automatic transmission, RPO MW7, install the exhaust pipe hanger bracket and bolt/stud and tighten to 25 Nm (18 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Page 3525 3. If equipped with a 4L80-E automatic transmission, RPO MT1, install the exhaust pipe hanger bracket and bolts and tighten to 25 Nm (18 lb ft). 4. If equipped with a 6.6L engine, install the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) ( See: Catalytic Converter/Service and Repair). 5. If equipped with a 6.0L engine, install the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side (Cab Chassis) (See: Catalytic Converter/Service and Repair). 6. If equipped with a 6.0L engine, install the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement (See: Exhaust Pipe/Service and Repair/Exhaust Manifold Pipe Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 07-06-05-001I > Mar > 11 > Exhaust Muffler Heat Shield Buzz During Operation Heat Shield: Customer Interest Exhaust - Muffler Heat Shield Buzz During Operation TECHNICAL Bulletin No.: 07-06-05-001I Date: March 22, 2011 Subject: V8 Engines - Muffler Heat Shield Buzz During Vehicle Operation (Perform Repair as Outlined) or Exhaust Pinging/Popping/Snapping Noise During Cool Down, at Idle, or After Vehicle is Shut Off (Normal Characteristic - No Repair Required) Models: 2007-2011 Cadillac Escalade, Escalade Hybrid, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Tahoe Hybrid 2007-2011 GMC Sierra, Sierra Denali, Yukon, Yukon Hybrid, Yukon XL, Yukon Denali, Yukon Denali XL Equipped with the following V8 Engines: - 4.8L (RPO LY2, L20) - 5.3L (RPOs LC9, LH6, LMG, LY5) - 6.0L (RPOs LFA, LY6, LZ1, L96) - 6.2L (RPOs L9H, L92, L94) Please Refer to GWM/IVH Supercede: This bulletin is being revised to update the Condition, Cause and Correction information. Please discard Corporate Bulletin Number 07-06-05-001H (Section 06 Engine/Propulsion System). Condition 1 Some customers may comment on a pinging/popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause 1 Exhaust Pinging/Popping/Snapping As the exhaust system cools, the muffler shell and muffler internals contract at different rates. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. Correction 1 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Exhaust Pinging/Popping/Snapping Noise (Normal) This condition is normal to the muffler design and does not indicate poor quality or part failure. No repairs are necessary for this condition. Replacing the muffler heat shield straps will NOT eliminate this noise. A new muffler may sound quiet for this condition, but as it ages may again produce this same condition. Condition 2 Some customers may also comment on a buzz noise coming from the muffler during vehicle operation. Cause 2 Muffler Heat Shield Buzz If the muffler heat shield straps are loose, the heat shield may be free to buzz during vehicle operation. Correction 2 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Muffler Heat Shield Buzz (Perform Repair) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 07-06-05-001I > Mar > 11 > Exhaust Muffler Heat Shield Buzz During Operation > Page 3534 Confirm the origin of the buzz by shimming (use metal shims) the straps tight and rerunning the vehicle. If the buzz concern is gone, then it is caused by the loose shield. Using the following procedure, install new straps to secure the heat shield to the muffler. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Mark the position of the heat shield (1) and straps (2) on the muffler shell. 3. Cut and remove the heat shield straps using tin snips along the muffler shell seam (1), and remove the shield from the muffler. 4. Position the heat shield to the muffler and install new heat shield straps on the muffler shell in the positions marked prior to removal. Important Do Not position the strap screw heads directly across from the propeller shaft. Ensure the strap heads are positioned below the midpoint of the muffler. 5. Position the strap screw heads (1) on the inboard side of the muffler. Ensure that the strap screw heads (1) are below the midpoint of the muffler. Tighten Tighten the straps to 4 Nm (35‹›lb‹›in). 6. Cut off the excess strap material and ensure that the ends (2) are flat against the muffler. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 07-06-05-001I > Mar > 11 > Exhaust Muffler Heat Shield Buzz During Operation > Page 3535 Warranty Information For vehicles with Exhaust Pinging/Popping/Snapping Noise, NO repairs are necessary as it is a normal condition. For vehicles repaired for a muffler buzz, use the labor operation. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation Heat Shield: All Technical Service Bulletins Exhaust - Muffler Heat Shield Buzz During Operation TECHNICAL Bulletin No.: 07-06-05-001I Date: March 22, 2011 Subject: V8 Engines - Muffler Heat Shield Buzz During Vehicle Operation (Perform Repair as Outlined) or Exhaust Pinging/Popping/Snapping Noise During Cool Down, at Idle, or After Vehicle is Shut Off (Normal Characteristic - No Repair Required) Models: 2007-2011 Cadillac Escalade, Escalade Hybrid, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Tahoe Hybrid 2007-2011 GMC Sierra, Sierra Denali, Yukon, Yukon Hybrid, Yukon XL, Yukon Denali, Yukon Denali XL Equipped with the following V8 Engines: - 4.8L (RPO LY2, L20) - 5.3L (RPOs LC9, LH6, LMG, LY5) - 6.0L (RPOs LFA, LY6, LZ1, L96) - 6.2L (RPOs L9H, L92, L94) Please Refer to GWM/IVH Supercede: This bulletin is being revised to update the Condition, Cause and Correction information. Please discard Corporate Bulletin Number 07-06-05-001H (Section 06 Engine/Propulsion System). Condition 1 Some customers may comment on a pinging/popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause 1 Exhaust Pinging/Popping/Snapping As the exhaust system cools, the muffler shell and muffler internals contract at different rates. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. Correction 1 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Exhaust Pinging/Popping/Snapping Noise (Normal) This condition is normal to the muffler design and does not indicate poor quality or part failure. No repairs are necessary for this condition. Replacing the muffler heat shield straps will NOT eliminate this noise. A new muffler may sound quiet for this condition, but as it ages may again produce this same condition. Condition 2 Some customers may also comment on a buzz noise coming from the muffler during vehicle operation. Cause 2 Muffler Heat Shield Buzz If the muffler heat shield straps are loose, the heat shield may be free to buzz during vehicle operation. Correction 2 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Muffler Heat Shield Buzz (Perform Repair) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation > Page 3541 Confirm the origin of the buzz by shimming (use metal shims) the straps tight and rerunning the vehicle. If the buzz concern is gone, then it is caused by the loose shield. Using the following procedure, install new straps to secure the heat shield to the muffler. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Mark the position of the heat shield (1) and straps (2) on the muffler shell. 3. Cut and remove the heat shield straps using tin snips along the muffler shell seam (1), and remove the shield from the muffler. 4. Position the heat shield to the muffler and install new heat shield straps on the muffler shell in the positions marked prior to removal. Important Do Not position the strap screw heads directly across from the propeller shaft. Ensure the strap heads are positioned below the midpoint of the muffler. 5. Position the strap screw heads (1) on the inboard side of the muffler. Ensure that the strap screw heads (1) are below the midpoint of the muffler. Tighten Tighten the straps to 4 Nm (35‹›lb‹›in). 6. Cut off the excess strap material and ensure that the ends (2) are flat against the muffler. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 07-06-05-001I > Mar > 11 > Exhaust - Muffler Heat Shield Buzz During Operation > Page 3542 Warranty Information For vehicles with Exhaust Pinging/Popping/Snapping Noise, NO repairs are necessary as it is a normal condition. For vehicles repaired for a muffler buzz, use the labor operation. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement - Right Side Exhaust Manifold Heat Shield Replacement - Right Side (V8) Removal Procedure 1. Remove the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 2. Remove the exhaust manifold heat shield bolts and heat shield from the exhaust manifold. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 3545 1. Position the exhaust manifold heat shield to the exhaust manifold and install the heat shield bolts. Tighten the bolts to 9 Nm (80 lb in). 2. Install the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 3546 Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement - Left Side Exhaust Manifold Heat Shield Replacement - Left Side (V8) Removal Procedure 1. Remove the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 2. Remove the exhaust manifold heat shield bolts and heat shield from the exhaust manifold. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 3547 1. Position the exhaust manifold heat shield to the exhaust manifold and install the heat shield bolts. Tighten the bolts to 9 Nm (80 lb in). 2. Install the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 3548 Heat Shield: Service and Repair Floor Panel Heat Shield Replacement Floor Panel Heat Shield Replacement Removal Procedure 1. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Catalytic Converter/Service and Repair). 2. If vehicle has a regular cab, remove the exhaust heat shield nuts. 3. Remove the exhaust front heat shield (1) and/or the rear exhaust heat shield (2) from the studs. 4. If vehicle has extended cab, remove the exhaust heat shield nuts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 3549 5. Remove the exhaust front heat shield (1) and/or the rear exhaust heat shield (2) from the studs. 6. If vehicle has a crew cab, remove the exhaust heat shield nuts. 7. Remove the exhaust front heat shield (1) and/or the rear exhaust heat shield (2) from the studs. Installation Procedure 1. If vehicle has a crew cab, position and install the rear exhaust heat shield (2) and/or the front exhaust heat shield (1) to the underbody studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust heat shield nuts and tighten to 9 Nm (80 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 3550 3. If vehicle has a extended cab, position and install the rear exhaust heat shield (2) and/or the front exhaust heat shield (1) to the underbody studs. 4. Install the exhaust heat shield nuts and tighten to 9 Nm (80 lb in). 5. If vehicle has a regular cab, position and install the rear exhaust heat shield (2) and/or the front exhaust heat shield (1) to the studs. 6. Install the exhaust heat shield nuts and tighten to 9 Nm (80 lb in). 7. Install the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Catalytic Converter/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 3551 Heat Shield: Service and Repair Exhaust Heat Shield Replacement - Dash Panel Exhaust Heat Shield Replacement - Dash Panel Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the exhaust heat shield nuts. 3. Remove both wheelhouse panels. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side) and Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 4. Remove the exhaust heat shield (1, 3) from the dash panel studs. 5. Remove the heat shield (1, 3) through the respective wheelwell. Installation Procedure 1. Install the heat shields (1, 3) through the respective wheelwell. 2. Install the exhaust heat shield (1, 3) to the dash panel studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the exhaust heat shield nuts and tighten to 9 Nm (80 lb in). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement Muffler: Service and Repair Exhaust Muffler Replacement Exhaust Muffler Replacement (1500 Series V6 or V8) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Lower the spare tire. 3. Remove the catalytic converter to exhaust muffler nuts. 4. If equipped with a exhaust muffler clamp (Norma), loosen the catalytic to exhaust muffler clamp nut (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3556 5. If equipped with a 4.8L engine, perform the following steps, otherwise proceed to step 7. 6. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease removal. 7. With the aid of an assistant, remove the insulators (1, 2) from the front and rear muffler assembly hangers. 8. Remove the insulator (1) from the intermediate muffler assembly hanger and remove the muffler assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3557 9. If equipped with a 5.3L, or a 6.0L engine, lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease removal. 10. With the aid of an assistant, remove the insulators (1, 2) from the front and rear muffler assembly hangers. Caution: During removal or installation, do not over extend the flex couple as internal damage may occur. 11. Remove the insulators (1) from the intermediate muffler assembly hangers and remove the muffler assembly. Pull the muffler assembly rearward until the flange is able to clear the front frame crossmember, and remove the muffler toward the front of the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3558 1. If equipped with a 4.8L engine, perform the following steps, otherwise proceed to step 6. 2. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease installation. Caution: During removal or installation, do not over extend the flex couple as internal damage may occur. 3. With the aid of an assistant, position and install the muffler assembly. 4. Install the insulators (1, 2) to the front and rear muffler assembly hangers. 5. Install the insulator (1) to the intermediate muffler assembly hanger. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3559 6. If equipped with a 5.3L, or a 6.0L engine, lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease installation. 7. With the aid of an assistant, position and install the muffler assembly. 8. Install the insulators (1, 2) to the front and rear muffler assembly hangers. 9. Install the insulator (1) to the intermediate muffler assembly hanger. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3560 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 10. Install the catalytic converter to exhaust muffler nuts and tighten to 45 Nm (33 lb ft). 11. For mufflers using an exhaust clamp (Norma), install the catalytic converter to the exhaust muffler and tighten clamp nut (1) to 28 Nm (21 lb ft). 12. Return the spare tire to the original position. 13. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3561 Muffler: Service and Repair Exhaust Muffler Replacement (Cab Chassis) Exhaust Muffler Replacement (Cab Chassis and 6.0L) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the spare tire, if necessary. 3. Install adjustable jack stands under the rear axle, if necessary. 4. If equipped with a 8.6 or a 9.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary. 5. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary. 6. If equipped with a 10.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary. 7. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary. 8. Remove the rear shock absorber lower bolts and nuts, if necessary. 9. Lower the rear axle using the adjustable jack stands, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3562 10. Remove the exhaust muffler to exhaust manifold pipe nuts (1). 11. Loosen the exhaust muffler clamp (3). 12. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series - Cab/Chassis) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair)Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair)Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (1500 Series) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair). 13. Lubricate the 4 insulators where the muffler assembly hangers are inserted in order to ease removal. 14. With the aid of an assistant, remove the insulators (1-4) from the front, intermediate, and rear muffler assembly hangers and remove the muffler assembly. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3563 1. Lubricate the 4 insulators where the muffler assembly hangers are inserted in order to ease installation. 2. With the aid of an assistant, position and install the muffler assembly. 3. Install the insulators (1-4) to the front, intermediate, and rear muffler assembly hangers. 4. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series - Cab/Chassis) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair)Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair)Heated Oxygen Sensor Replacement Bank 2 Sensor 2 (1500 Series) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the exhaust muffler clamp (3) to 47 Nm (35 lb ft). 6. Install the exhaust muffler to exhaust manifold pipe nuts (1) and tighten to 45 Nm (33 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3564 7. Raise the rear axle using the adjustable jack stands, if necessary. 8. Install the rear shock absorber lower bolts and nuts, if necessary and tighten to 95 Nm (70 lb ft). 9. If equipped with a 10.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary. 10. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary. 11. If equipped with a 8.6 or a 9.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary. 12. Install the vent hose swivel clip to the rear brake crossover pipe, if necessary. 13. Remove the adjustable jack stands from under the rear axle, if necessary. 14. Install the spare tire, if necessary. 15. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Exhaust Seal Replacement Exhaust Pipe Gasket: Service and Repair Exhaust Seal Replacement Exhaust Seal Replacement (V8) Removal Procedure 1. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Catalytic Converter/Service and Repair). 2. Remove and discard the appropriate exhaust seal (1 or 2). (1500 series shown, 2500 series similar). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Exhaust Seal Replacement > Page 3570 1. Install the NEW appropriate exhaust seal (1 or 2). (1500 series shown, 2500 series similar). 2. Install the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Catalytic Converter/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Exhaust Seal Replacement > Page 3571 Exhaust Pipe Gasket: Service and Repair Exhaust Seal Replacement (ZW9 Cab Chassis) Exhaust Seal Replacement (ZW9 Cab Chassis) Removal Procedure 1. Remove the left catalytic converter, if required. Refer to Catalytic Converter Replacement - Left Side (Cab Chassis) (See: Catalytic Converter/Service and Repair). 2. Remove the exhaust manifold pipe, if required. Refer to Exhaust Manifold Pipe Replacement (See: Exhaust Pipe/Service and Repair/Exhaust Manifold Pipe Replacement). 3. Remove and discard the appropriate exhaust seal (1) or gasket (2). Installation Procedure 1. Install the NEW appropriate exhaust seal (1) or gasket (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Exhaust Seal Replacement > Page 3572 2. Install the exhaust manifold pipe, if required. Refer to Exhaust Manifold Pipe Replacement (See: Exhaust Pipe/Service and Repair/Exhaust Manifold Pipe Replacement). 3. Install the left catalytic converter, if required. Refer to Catalytic Converter Replacement - Left Side (Cab Chassis) (See: Catalytic Converter/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 3588 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 3599 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3600 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3601 Body Control Module (BCM) X2 Body Control Module (BCM) X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3602 Body Control Module (BCM) X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3603 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3604 Body Control Module (BCM) X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3605 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3606 Body Control Module (BCM) X6 Body Control Module (BCM) X7 (except MEX or A52) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3607 Auxiliary Body Control Module (XBCM) X1 (EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3608 Auxiliary Body Control Module (XBCM) X2 (EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3609 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 3612 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 3613 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 3614 Body Control Module: Service and Repair Serial Data Gateway Module Replacement Serial Data Gateway Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 3628 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 3633 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 3634 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 3635 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 3644 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 3645 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 3646 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 3652 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 3657 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 3658 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 3659 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 3664 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 3665 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission Aftermarket Calibrations > Page 3666 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3667 Engine Control Module: Locations Harness Routing Views Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3668 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Engine Harness Routing - Top (4.3L) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3669 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3670 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3671 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3672 Engine Control Module (ECM) X1 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3673 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3674 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3675 Engine Control Module (ECM) X1 (LY2, LMG, LC9, LY5, LH6, L76 or L9H) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3676 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3677 Engine Control Module (ECM) X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3678 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3679 Engine Control Module (ECM) X1 (LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3680 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3681 Engine Control Module (ECM) X2 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3682 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3683 Engine Control Module (ECM) X2 (LY2, LY6 or L9H with Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3684 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3685 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3686 Engine Control Module (ECM) X2 (LMG, LC9, LY5, LH6, L76 or L9H without Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3687 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3688 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3689 Engine Control Module (ECM) X2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3690 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3691 Engine Control Module (ECM) X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3692 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3693 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3694 Engine Control Module (ECM) X3 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3695 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3696 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3697 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3698 Engine Control Module: Service and Repair Engine Control Module Replacement Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: Record the current Engine Oil Life percentage, and use a scan tool to update the NEW ECM, if replacing. Removal Procedure 1. Record the current Engine Oil Life percentage, and use a scan tool to update the NEW ECM, if replacing. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Disengage the engine wiring harness upper electrical connector retainer (2) and remove the connector (1) from the ECM. 4. Disengage the engine wiring harness lower electrical connector retainer (3) and remove the connector (4) from the ECM. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3699 5. Disengage the retainer tabs securing the ECM to the bracket. 6. Remove the ECM. Installation Procedure 1. Install the bottom ECM tabs into the bracket. 2. Push the ECM in securing the ECM to the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3700 3. Position the engine wiring harness lower electrical connector and engage the retainer (3) securing the lower connector (4) to the ECM. 4. Position the engine wiring harness upper electrical connector and engage the retainer (2) securing the upper connector (1) to the ECM. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 6. If a NEW ECM was installed, program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3704 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3705 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3706 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3707 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3708 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3709 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3710 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module (Gas except JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams > Page 3715 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood Fuel Pump Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 3720 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 3721 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 3722 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 3723 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 3724 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 3725 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 3726 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 3727 Fuel Pump Relay: Locations Harness Routing Views Harness Routing Views Chassis Harness - Front Engine Compartment (31 Series) 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3728 Fuel Pump Relay: Diagrams Component Connector End Views Fuel Pump Relay - Secondary (LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3732 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3733 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3734 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3735 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3736 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3737 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3738 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams Ignition Control Module: Diagrams Component Connector End Views Ignition Control Module (ICM) (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3748 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3749 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 2. Remove the accelerator pedal bolts. 3. Remove the accelerator pedal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3750 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3754 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3755 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3756 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3757 Installation Procedure Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the MAF/IAT sensor adapter clamp. Tighten the clamp to 4 Nm (35 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 3761 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 3762 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3766 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3767 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3768 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3769 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3770 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3771 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement (Except RPOs LY2, LY5, LH6 and LMG) Removal Procedure Note: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the CMP sensor wire harness. 3. Remove the 3 CMP sensor wire harness bolts (738). 4. Disconnect the CMP sensor wire harness electrical connectors from the CMP sensor and the CMP actuator magnet. 5. Remove the CMP sensor wire harness (737). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3772 6. Remove the CMP sensor (703) and O-ring seal (704). Installation Procedure 1. Inspect the CMP O-ring seal for cuts or damage. If the seal is not cut or damaged, it may be used again. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal (704) onto the sensor. 4. Instal the CMP sensor (703) to the front cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3773 5. Install the CMP sensor wire harness (737). 6. Connect the CMP sensor wire harness electrical connectors to the CMP sensor and the CMP actuator magnet. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the 3 CMP sensor wire harness bolts (738). Tighten the bolts to 12 Nm (106 lb in). 8. Connect the engine wiring harness electrical connector (1) to the CMP sensor wire harness. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Clutch Switch: Diagrams Component Connector End Views Clutch Pedal Position (CPP) Switch (TZ0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3785 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3786 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3787 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3788 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3794 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3795 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3796 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3797 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3798 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3799 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor. 3. Remove the ECT sensor. Installation Procedure Caution: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3800 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ECT sensor and tighten to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor. 4. Refill the cooling. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3804 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3805 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3806 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The Crankshaft Position System Variation Learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * An engine replacement * A engine control module (ECM) replacement * A crankshaft balancer replacement * A crankshaft replacement * A crankshaft position sensor replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The ECM monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position System Variation Learn Procedure. 1. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 2. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 3. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 4. Enable the CKP System Variation Learn Procedure with a scan tool. 5. Quickly apply and release the accelerator pedal. 6. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 7. The scan tool displays Learn Status: Learned this ignition. 8. Once the Learn Procedure has successfully completed, and in order to store the crankshaft position system variation values in the ECM, turn OFF the ignition and verify all vehicle systems are OFF. This may take up to 2 minutes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3807 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure Note: Perform the Crankshaft Position System Variation Learn (See: Testing and Inspection) whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3808 5. Remove the CKP sensor. Installation Procedure 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 3813 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 3814 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) ( See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 3815 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Reg Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Reg Cab With 26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 3816 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 3817 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) ( See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 3818 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 gal Tank) Fuel Level Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 gal Tnk) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 3819 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 3820 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) ( See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 Gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 3826 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 3827 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 REG Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Reg Cab With 26 Gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 3828 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 3829 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15/25 REG/Ext/Crw Cab With 34 gal Tank) Fuel Tank Pressure Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 3830 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Page 3834 Installation Procedure Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the MAF/IAT sensor adapter clamp. Tighten the clamp to 4 Nm (35 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3838 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3841 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (4) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3842 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3843 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (2) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (LU3) Manifold Absolute Pressure (MAP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 3847 Manifold Absolute Pressure (MAP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 3848 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 3849 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (4) from the manifold absolute pressure (MAP) sensor. 3. Remove the MAP sensor retainer. 4. Remove the MAP sensor. Installation Procedure Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 3850 1. Install the MAP sensor. 2. Install the MAP sensor retainer. 3. Connect the engine harness wiring electrical connector (4) to the MAP sensor. 4. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 3854 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 3855 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 3856 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 3857 washer (707). 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 3858 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Harness Routing Views Heated Oxygen Sensor (HO2S) Jumper Harness Routing (LY6) 1 - X125 2 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3862 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LU3) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (Gas except LU3 and except ZW9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3863 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY6 or L96 with ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3864 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (Gas except LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3865 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (Gas except LU3 and except ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY6 or L96 with ZW9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3866 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3867 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 3870 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 3871 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 3872 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Unbolt the front propeller shaft from the front differential, if equipped with four wheel drive (4WD). Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 3. For vehicles equipped with a 4L60-E/4L70-E automatic transmission perform the following steps, for vehicles equipped with a 6L80-E automatic transmission proceed to step 7. 4. Remove the connector position assurance (CPA) retainer. 5. Disconnect the engine wiring harness electrical connector (2) from the HO2S. 6. Remove the HO2S electrical connector clip (1) from the fuel line clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 3875 7. Remove the CPA retainer (2). 8. Remove the engine wiring harness electrical connector clip (1) from the fuel line clip. 9. Disconnect the engine wiring harness electrical connector (3) from the HO2S. Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 10. Remove the HO2S (1 or 2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 3876 Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 2. Install the HO2S (1 or 2). Tighten the sensor to 42 Nm (31 lb ft). 3. For vehicles equipped with a 4L60-E/4L70-E automatic transmission perform the following steps, for vehicles equipped with a 6L80-E automatic transmission proceed to step 7. 4. Install the HO2S electrical connector clip (1) to the fuel line clip. 5. Connect the engine wiring harness electrical connector (2) to the HO2S. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 3877 6. Install the CPA retainer. 7. Connect the engine wiring harness electrical connector (3) to the HO2S. 8. Install the engine wiring harness electrical connector clip (1) to the fuel line clip. 9. Install the CPA retainer (2). 10. Install the front propeller shaft to the front differential, if equipped with 4WD. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 11. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 3878 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the connector position assurance (CPA) retainer (1). 3. Disconnect the HO2S electrical connector from the engine wiring harness electrical connector (3). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 4. Remove the HO2S (5). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 3879 Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 2. Install the HO2S (5). Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the HO2S electrical connector to the engine wiring harness electrical connector (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 3880 4. Install the CPA retainer (1). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 3881 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) 1. Remove the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 2. Remove the connector position assurance (CPA) retainer (2). 3. Disconnect the HO2S electrical connector (7) from the engine wiring harness electrical connector (1). 4. Remove the HO2S clip (8) from the engine wiring harness. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 3882 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) 5. Remove the HO2S (3). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution) 2. Install the HO2S (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 3883 Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the HO2S electrical connector (7) to the engine wiring harness electrical connector (1). 4. Install the CPA retainer (2). 5. Install the HO2S clip (8) to the engine wiring harness. 6. Install the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 3884 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the connector position assurance (CPA) retainer (5). 3. Disconnect the engine wiring harness electrical connector (4) from the HO2S electrical connector (3). 4. Remove the HO2S electrical connector clip from the engine harness clip (6). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 3885 5. Remove the HO2S (4). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution) 2. Install the HO2S (4). Tighten the sensor to 42 Nm (31 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 3886 3. Install the HO2S electrical connector clip to the engine harness clip (6). 4. Connect the engine wiring harness electrical connector (4) to the HO2S electrical connector (3). 5. Install the CPA retainer (5). 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Parking Lock and Manual Shift Detent Lever with Shaft Position Switch Assembly 78 - Steel Cup Plug 79 - Parking Brake Pawl Shaft 80 - Parking Pawl Return Spring 81 - Parking Brake Pawl 82 - Manual Shaft Seal 84 - Manual Shaft - Model Dependent 85 - Parking Lock Actuator Assembly 86 - Parking Lock Bracket 87 - Parking Lock Bracket Bolt 88 - Manual Shift Detent Lever with Shaft Position Switch Assembly 89 - Manual Valve Link 92 - Manual Shift Detent Lever Hub Pin Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3891 Transmission Position Switch/Sensor: Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3892 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3895 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3896 Transmission Position Switch/Sensor: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 Nm (9 lb ft). 3. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Install the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3897 Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations Vehicle Speed Sensor: Component Locations Disassembled Views Case and Associated Parts (1 of 2) 1 - Torque Converter Assembly - Size Model Dependent 2 - Pump to Case Bolt 3 - Pump to Case Bolt O-Ring 4 - Oil Pump Assembly 5 - A/T Fluid Pump Seal - Pump to Case 6 - Pump Cover to Case Gasket 7 - Case Bushing 9 - Transmission Vent Assembly 11 - Case Servo Plug 12 - Servo Return Spring 13 - 2nd Apply Piston Pin 14 - Retainer Ring - 2nd Apply Piston 15 - Servo Cushion Spring Retainer 16 - Servo Cushion Spring - Outer 17 - 2nd Apply Piston 18 - Oil Seal Ring - 2nd Apply Piston - Outer 19 - Oil Seal Ring - 2nd Apply Piston - Inner Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 3902 20 - Servo Piston Housing - Inner 21 - O-Ring Seal 22 - Servo Apply Pin Spring 23 - Servo Apply Pin Washer 24 - Retainer Ring - Apply Pin 25 - 4th Apply Piston 26 - Oil Seal Ring - 4th Apply Piston - Outer 27 - O-Ring Seal - 2-4 Servo Cover 28 - 2-4 Servo Cover 29 - Servo Cover Retaining Ring 30 - Case Extension to Case Seal 31 - Case Extension - Model Dependent 32 Case Extension to Case Bolt 33 - Case Extension Bushing 34 - Case Extension Oil Seal Assembly - Model Dependent 34 - Case Extension Oil Seal Assembly - Model Dependent 35 - Speed Sensor Retaining Bolt 36 - Vehicle Speed Sensor (VSS) 37 - O-Ring Seal - VSS to Case Extension 71 Filter Seal 72 - Transmission Oil Filter Assembly - Model Dependent 73 - Transmission Oil Pan Gasket 74 - Chip Collector Magnet 75 - Transmission Oil Pan - Model Dependent 76 Transmission Oil Pan Screw 94 - Converter Housing to Case Bolt 95 - Oil Cooler Quick Connector 96 - Oil Cooler Quick Connect Clip 97 - Converter Housing Access Hole Plug - Model Dependent 98 - Converter Bolt Inspection Plate - Model Dependent 99 - Cup D4 Orifice Plug 102 - Converter Housing - Model Dependent 103 - Main Section Case - Model Dependent 105 - Servo Cushion Spring - Inner - Model Dependent Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 3903 Vehicle Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3904 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) (M30, TZ0, MYC and MW7or M99 with NQG or NQF) Vehicle Speed Sensor (VSS) (MW7 except NQG or NQF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3905 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the VSS bolt (2). Tighten the bolt to 11 Nm (97 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3908 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3909 Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3910 Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3911 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the VSS and O-ring seal. Tighten the VSS to 16 Nm (12 lb ft). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3912 Vehicle Speed Sensor: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3913 Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the VSS bolt (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3914 Tighten the bolt to 11 Nm (97 lb in). 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3915 Tremec 5-Speed (TZ0) - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3916 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the VSS and O-ring seal. Tighten the VSS to 16 Nm (12 lb ft). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3917 MP 1625/1626-NQF - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3918 MP 3023/3024-NQH - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 3919 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3924 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3925 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 2. Remove the accelerator pedal bolts. 3. Remove the accelerator pedal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3926 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3930 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3931 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3932 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3933 Installation Procedure Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the MAF/IAT sensor adapter clamp. Tighten the clamp to 4 Nm (35 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3936 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3937 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3938 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3939 Installation Procedure Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the MAF/IAT sensor adapter clamp. Tighten the clamp to 4 Nm (35 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams Fuel Pressure Sensor/Switch: Diagrams Component Connector End Views Fuel Pressure Sensor (Gas except LU3 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 3943 Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the chassis wiring harness electrical connector (1) from the fuel pressure sensor. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. 4. Remove the fuel pressure sensor from the fuel line. 5. Remove and discard the fuel pressure sensor O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 3944 1. Lubricate a NEW fuel pressure sensor O-ring seal with clean engine oil. 2. Install the NEW fuel pressure sensor O-ring seal onto the fuel line fitting. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the fuel pressure sensor to the fuel line. Tighten the sensor to 15 Nm (11 lb ft). 5. Connect the chassis wiring harness electrical connector (1) to the fuel pressure sensor. 6. Lower the vehicle. 7. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 3945 4. Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3950 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3951 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3952 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3953 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3954 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3955 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement (Except RPOs LY2, LY5, LH6 and LMG) Removal Procedure Note: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the CMP sensor wire harness. 3. Remove the 3 CMP sensor wire harness bolts (738). 4. Disconnect the CMP sensor wire harness electrical connectors from the CMP sensor and the CMP actuator magnet. 5. Remove the CMP sensor wire harness (737). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3956 6. Remove the CMP sensor (703) and O-ring seal (704). Installation Procedure 1. Inspect the CMP O-ring seal for cuts or damage. If the seal is not cut or damaged, it may be used again. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal (704) onto the sensor. 4. Instal the CMP sensor (703) to the front cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3957 5. Install the CMP sensor wire harness (737). 6. Connect the CMP sensor wire harness electrical connectors to the CMP sensor and the CMP actuator magnet. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the 3 CMP sensor wire harness bolts (738). Tighten the bolts to 12 Nm (106 lb in). 8. Connect the engine wiring harness electrical connector (1) to the CMP sensor wire harness. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3961 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3962 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3963 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The Crankshaft Position System Variation Learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * An engine replacement * A engine control module (ECM) replacement * A crankshaft balancer replacement * A crankshaft replacement * A crankshaft position sensor replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The ECM monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position System Variation Learn Procedure. 1. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 2. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 3. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 4. Enable the CKP System Variation Learn Procedure with a scan tool. 5. Quickly apply and release the accelerator pedal. 6. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 7. The scan tool displays Learn Status: Learned this ignition. 8. Once the Learn Procedure has successfully completed, and in order to store the crankshaft position system variation values in the ECM, turn OFF the ignition and verify all vehicle systems are OFF. This may take up to 2 minutes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3964 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure Note: Perform the Crankshaft Position System Variation Learn (See: Testing and Inspection) whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3965 5. Remove the CKP sensor. Installation Procedure 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 3971 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 3972 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note: The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 3973 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3977 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3980 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (4) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3981 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 3982 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (2) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Service Precautions Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) Fuel Pressure: Testing and Inspection Fuel System Diagnosis (FPCM) Fuel System Diagnosis (FPCM) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for 2 seconds, unless the engine is in Crank or Run. While this voltage is being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure. The fuel system is an electronic returnless on-demand design. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump is contained by the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pump module contains a reverse flow check valve. The check valve maintains fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Reference Information Description and Operation Fuel System Description (See: Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH-48027 Digital Pressure Gauge * J 37287 Fuel Line Shut-off Adapter Circuit/System Verification Note: * Repair all fuel system related DTCs before performing this diagnostic, unless instructed here from a DTC diagnostic. * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. * DO NOT perform the Fuel System Diagnosis if the engine coolant temperature is above 60°C (150°F). High fuel pressure readings may result due to hot soak fuel boiling. With the engine OFF, the fuel pressure may increase beyond the pressure relief valves set point of 690 kPa = / -5 % (100 psi ±5 %). 1. Ignition OFF, all accessories OFF, install a CH-48027 . Refer to Fuel Pressure Gauge Installation and Removal (See: Fuel Pressure Gauge Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) > Page 3989 Installation and Removal). 2. Ignition ON, engine OFF, command the fuel pump ON with a scan tool. Verify the fuel pressure is between 345-690 kPa (50-100 psi) with the pump running. 3. Engine ON with the engine idling at normal operating temperature, the Fuel Rail Pressure Sensor parameter should read between 296.4-310.3 kPa (43-45 psi). Circuit/System Testing Note: * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, engine OFF, command the fuel pump ON with a scan tool and observe the fuel pressure gauge while the fuel pump is operating. Verify the fuel pressure is between 345-690 kPa (50-100 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 2. Verify that the fuel pressure, after the fuel pump is turned off, decreases to 500-599 kPa (72-87 psi), and does not decrease more than 34 kPa (5 psi) in 1 minute from that point. ‹› If the fuel pressure stays above 600 kPa (87 psi), replace the fuel pump module. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair ). 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 . 4. Ignition ON, command the fuel pump ON with a scan tool and bleed the air from the CH-48027 . 5. Command the fuel pump ON and then OFF with a scan tool. 6. Close the valve on the J 37287 . 7. Monitor the fuel pressure for 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module. 4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with the CH-48027 . The fuel pressure should not drop off during acceleration, cruise or hard cornering. ‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections 5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) > Page 3990 Fuel Pressure: Testing and Inspection Fuel Pressure Gauge Installation and Removal Fuel Pressure Gauge Installation and Removal Special Tools CH-48027 Digital Pressure Gauge Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions. Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) > Page 3991 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 3995 Idle Speed: Testing and Inspection Throttle/Idle Learn Description The engine control module (ECM) learns the airflow through the throttle body to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to throttle body coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned. An engine that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero. The idle may be unstable or a DTC may set if the learned values do not match the actual airflow. Conditions for Running the Throttle Learn Procedure Reset Procedure * DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set. * Ignition ON, engine OFF. * The vehicle speed sensor (VSS) is 0 km/h (0 mph). Learn Procedure * DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set. * The engine speed is between 450-4,000 RPM. * The manifold absolute pressure (MAP) is greater than 5 kPa. * The mass air flow (MAF) is greater than 2 g/s. * The ignition voltage is greater than 10 volts. Throttle Learn Reset Procedure (Performed after the throttle body is cleaned or replaced) 1. Ignition ON, engine OFF, perform the Idle Learn Reset in Module Setup with a scan tool. 2. Start the engine and monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation value should equal 0 percent and the engine should be idling at a normal idle speed. 3. Clear the DTCs and return to the diagnostic that referred you here. Learn Procedure (Performed after the ECM is flashed or replaced) Note: Do NOT perform this procedure if DTCs are set. Refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle). 1. Start and idle the engine for 3 minutes. 2. With a scan tool, monitor the Desired Idle Speed and the actual Engine Speed. 3. The ECM will start to learn the new idle cells and Desired Idle Speed should start to decrease. 4. Ignition OFF for 60 seconds. 5. Start and idle the engine for 3 minutes. 6. After the 3 minute run time the engine should be idling normal. Note: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. ‹› If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles. 7. After the drive cycle, the engine should be idling normally. ‹› If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6. 8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that referred you here. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Resonator Outlet Duct Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct. 3. Remove the radiator inlet hose clamp retainer from the outlet duct. 4. Loosen the air cleaner outlet duct clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 5. Loosen the air cleaner outlet duct clamp (2) at the throttle body. 6. Lift up the air cleaner outlet duct at the resonator tab in order to separate the resonator from the stud on the intake manifold. 7. Remove the air cleaner outlet duct from the throttle body and MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 4000 Installation Procedure 1. Install the air cleaner outlet duct to the throttle body and MAF/IAT sensor. Ensure that the resonator tab aligns with the stud on the intake manifold. 2. Push down on the air cleaner outlet duct resonator directly over the resonator tab in order to secure the resonator to the stud on the intake manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 3. Tighten the air cleaner outlet duct clamp (2) at the throttle body to 4 Nm(35 lb in). 4. Tighten the air cleaner outlet duct clamp (1) to 4 Nm(35 lb in) at the MAF/IAT sensor. 5. Install the radiator inlet hose clamp retainer to the outlet duct. 6. Install the PCV line (1) to the air cleaner outlet duct. 7. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief (CH-48027) Special Tools CH-48027 - Digital Pressure Gauge Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 4008 * The hose connections * The areas surrounding the connections Note: If relieving the fuel pressure for the fuel pressure gauge installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Ignition System Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires, Incorrect routing may cause cross firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for any of the following conditions: * Tearing * Piercing * Arcing * Carbon tracking * Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 4015 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 4016 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Ignition System Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4020 Spark Plug: Application and ID Ignition System Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4021 Spark Plug: Testing and Inspection Spark Plug Inspection * Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Ignition System/Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling, replace with a colder plug - Pre-ignition causing spark plug and/or engine damage , replace with a hotter plug * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. * Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4022 * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications (See: Ignition System/Specifications). An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Ignition System/Specifications). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection * Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak ignition coils * Worn ignition wires * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4023 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Brush or using compressed air, blow away any dirt from around the spark plug. 3. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4024 1. Inspect the spark plug gap. Adjust the gap as needed. Refer to Ignition System Specifications (See: Ignition System/Specifications). 2. Hand start the spark plug in the corresponding cylinder. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the spark plug to 15 Nm (11 lb ft). 4. Install the spark plug wire to the spark plug. 5. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 4028 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gauge at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4033 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4034 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 2. Remove the accelerator pedal bolts. 3. Remove the accelerator pedal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4035 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4039 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4040 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4041 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4042 Installation Procedure Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the MAF/IAT sensor adapter clamp. Tighten the clamp to 4 Nm (35 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Page 4046 Installation Procedure Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the MAF/IAT sensor adapter clamp. Tighten the clamp to 4 Nm (35 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 4050 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 4051 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-42-006E > Nov > 10 > Instruments Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 4069 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 4075 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 4081 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4082 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4083 Body Control Module (BCM) X2 Body Control Module (BCM) X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4084 Body Control Module (BCM) X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4085 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4086 Body Control Module (BCM) X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4087 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4088 Body Control Module (BCM) X6 Body Control Module (BCM) X7 (except MEX or A52) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4089 Auxiliary Body Control Module (XBCM) X1 (EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4090 Auxiliary Body Control Module (XBCM) X2 (EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4091 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 4094 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 4095 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 4096 Body Control Module: Service and Repair Serial Data Gateway Module Replacement Serial Data Gateway Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4100 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4101 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4102 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4103 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4104 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4105 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement (Except RPOs LY2, LY5, LH6 and LMG) Removal Procedure Note: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the CMP sensor wire harness. 3. Remove the 3 CMP sensor wire harness bolts (738). 4. Disconnect the CMP sensor wire harness electrical connectors from the CMP sensor and the CMP actuator magnet. 5. Remove the CMP sensor wire harness (737). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4106 6. Remove the CMP sensor (703) and O-ring seal (704). Installation Procedure 1. Inspect the CMP O-ring seal for cuts or damage. If the seal is not cut or damaged, it may be used again. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal (704) onto the sensor. 4. Instal the CMP sensor (703) to the front cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4107 5. Install the CMP sensor wire harness (737). 6. Connect the CMP sensor wire harness electrical connectors to the CMP sensor and the CMP actuator magnet. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the 3 CMP sensor wire harness bolts (738). Tighten the bolts to 12 Nm (106 lb in). 8. Connect the engine wiring harness electrical connector (1) to the CMP sensor wire harness. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Clutch Switch: Diagrams Component Connector End Views Clutch Pedal Position (CPP) Switch (TZ0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4119 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4120 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4121 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4122 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4128 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4129 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4130 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4131 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4132 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4133 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor. 3. Remove the ECT sensor. Installation Procedure Caution: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4134 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ECT sensor and tighten to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor. 4. Refill the cooling. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4138 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4139 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4140 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The Crankshaft Position System Variation Learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * An engine replacement * A engine control module (ECM) replacement * A crankshaft balancer replacement * A crankshaft replacement * A crankshaft position sensor replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The ECM monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position System Variation Learn Procedure. 1. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 2. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 3. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 4. Enable the CKP System Variation Learn Procedure with a scan tool. 5. Quickly apply and release the accelerator pedal. 6. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 7. The scan tool displays Learn Status: Learned this ignition. 8. Once the Learn Procedure has successfully completed, and in order to store the crankshaft position system variation values in the ECM, turn OFF the ignition and verify all vehicle systems are OFF. This may take up to 2 minutes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4141 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure Note: Perform the Crankshaft Position System Variation Learn (See: Testing and Inspection) whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4142 5. Remove the CKP sensor. Installation Procedure 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams Data Link Connector: Diagrams Component Connector End Views Data Link Connector (DLC) Data Link Resistor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 4146 Data Link Resistor 2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Description and Operation Electronic Throttle Actuator: Description and Operation Throttle Actuator Control (TAC) System Description The engine control module (ECM) is the control center for the throttle actuator control (TAC) system. The ECM determines the driver's intent based on input from the accelerator pedal position sensors, then calculates the appropriate throttle response based on the throttle position sensors. The ECM achieves throttle positioning by providing a pulse width modulated voltage to the throttle actuator motor. The throttle blade is spring loaded in both directions, and the default position is slightly open. Modes Of Operation Normal Mode During the operation of the TAC system, several modes, or functions, are considered normal. The following modes may be entered during normal operations: * Minimum pedal value-At key-up, the ECM updates the learned minimum pedal value. * Minimum throttle position values-At key-up, the ECM updates the learned minimum throttle position value. In order to learn the minimum throttle position value, the throttle blade is moved to the Closed position. * Ice break mode-If the throttle blade is not able to reach a predetermined minimum throttle position, the ice break mode is entered. During the ice break mode, the ECM commands the maximum pulse width several times to the throttle actuator motor in the closing direction. * Minimum pedal value-At key-up, the ECM updates the learned minimum pedal value. * Battery saver mode-After a predetermined time without engine RPM, the ECM commands the Battery Saver mode. During the Battery Saver mode, the TAC module removes the voltage from the motor control circuits, which removes the current draw used to maintain the idle position and allows the throttle to return to the spring loaded default position. Reduced Engine Power Mode When the ECM detects a condition with the TAC system, the ECM may enter a reduced engine power mode. Reduced engine power may cause one or more of the following conditions: * Acceleration limiting-The ECM will continue to use the accelerator pedal for throttle control, however, the vehicle acceleration is limited. * Limited throttle mode-The ECM will continue to use the accelerator pedal for throttle control, however, the maximum throttle opening is limited. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Description and Operation > Page 4150 * Throttle default mode-The ECM will turn OFF the throttle actuator motor, and the throttle will return to the spring loaded default position. * Forced idle mode-The ECM will perform the following actions: - Limit engine speed to idle positioning the throttle position, or by controlling the fuel and spark if the throttle is turned OFF. - Ignore the accelerator pedal input. * Engine shutdown mode-The ECM will disable fuel and de-energize the throttle actuator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-03-10-008B > Jul > 10 > Wheels/Tires Module Programming For 20/22 Inch Wheels Engine Control Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 4164 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4169 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4170 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4171 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4180 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4181 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4182 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 4188 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4193 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4194 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4195 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4200 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4201 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4202 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4203 Engine Control Module: Locations Harness Routing Views Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4204 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Engine Harness Routing - Top (4.3L) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4205 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4206 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4207 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4208 Engine Control Module (ECM) X1 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4209 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4210 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4211 Engine Control Module (ECM) X1 (LY2, LMG, LC9, LY5, LH6, L76 or L9H) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4212 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4213 Engine Control Module (ECM) X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4214 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4215 Engine Control Module (ECM) X1 (LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4216 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4217 Engine Control Module (ECM) X2 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4218 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4219 Engine Control Module (ECM) X2 (LY2, LY6 or L9H with Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4220 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4221 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4222 Engine Control Module (ECM) X2 (LMG, LC9, LY5, LH6, L76 or L9H without Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4223 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4224 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4225 Engine Control Module (ECM) X2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4226 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4227 Engine Control Module (ECM) X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4228 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4229 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4230 Engine Control Module (ECM) X3 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4231 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4232 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4233 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4234 Engine Control Module: Service and Repair Engine Control Module Replacement Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: Record the current Engine Oil Life percentage, and use a scan tool to update the NEW ECM, if replacing. Removal Procedure 1. Record the current Engine Oil Life percentage, and use a scan tool to update the NEW ECM, if replacing. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Disengage the engine wiring harness upper electrical connector retainer (2) and remove the connector (1) from the ECM. 4. Disengage the engine wiring harness lower electrical connector retainer (3) and remove the connector (4) from the ECM. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4235 5. Disengage the retainer tabs securing the ECM to the bracket. 6. Remove the ECM. Installation Procedure 1. Install the bottom ECM tabs into the bracket. 2. Push the ECM in securing the ECM to the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4236 3. Position the engine wiring harness lower electrical connector and engage the retainer (3) securing the lower connector (4) to the ECM. 4. Position the engine wiring harness upper electrical connector and engage the retainer (2) securing the upper connector (1) to the ECM. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 6. If a NEW ECM was installed, program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4241 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4242 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) ( See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4243 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Reg Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Reg Cab With 26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4244 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4245 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) ( See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4246 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 gal Tank) Fuel Level Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 gal Tnk) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4247 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4248 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) ( See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 Gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4254 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4255 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 REG Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Reg Cab With 26 Gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4256 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4257 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15/25 REG/Ext/Crw Cab With 34 gal Tank) Fuel Tank Pressure Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4258 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Specifications Information Bus: Specifications Fastener Tightening Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4264 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4265 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4266 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4267 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4268 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4269 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4270 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4271 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4272 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4273 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4274 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4275 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4276 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4277 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4278 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4279 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4280 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4281 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4282 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4283 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4284 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4285 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4286 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4287 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4288 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4289 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4290 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4291 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4292 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4293 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4294 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4295 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4296 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4297 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4298 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4299 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4300 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4301 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4302 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4303 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4304 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4305 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4306 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4307 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4308 Information Bus: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4309 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4310 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4311 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4312 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4313 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4314 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4315 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4316 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4317 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4318 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4319 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4320 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4321 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4322 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4323 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4324 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4325 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4326 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4327 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4328 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4329 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4330 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4331 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4332 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4333 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4334 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4335 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4336 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4337 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4338 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4339 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4340 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4341 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4342 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4343 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4344 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4345 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4346 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4347 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4348 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4349 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4350 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4351 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4352 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4353 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4354 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4355 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4356 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4357 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4358 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4359 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4364 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4365 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4366 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4367 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4368 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4369 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4370 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4371 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4372 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4373 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4374 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4375 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4376 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4377 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4378 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4379 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4380 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4381 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4382 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4383 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4384 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4385 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4386 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4387 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4388 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4389 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4390 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4391 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4392 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4393 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4394 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4395 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4396 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4397 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4398 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4399 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4400 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4401 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4402 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4403 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4404 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4405 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4406 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4407 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4408 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4409 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4410 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4411 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4412 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4413 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4414 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4415 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4416 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4417 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4418 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4419 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4420 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4421 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4422 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4423 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4424 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4425 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4426 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4427 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4428 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4429 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4430 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4431 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4432 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4433 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4434 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4435 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4436 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4437 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4438 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4439 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4440 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4441 Information Bus: Connector Views Component Connector End Views Serial Data Gateway (SDG) Module X1 (HP2) Serial Data Gateway (SDG) Module X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4442 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4443 Information Bus: Electrical Diagrams Data Communication Schematics Low Speed Bus - 1 of 3 Low Speed Bus - 2 of 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4444 Low Speed Bus - 3 of 3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4445 High Speed Bus - 1 of 6 (except MEX/HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4446 High Speed Bus - 2 of 6 (except MEX/HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4447 High Speed Bus - 3 of 6 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4448 High Speed Bus - 4 of 6 (MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4449 High Speed Bus - 5 of 6 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4450 High Speed Bus - 6 of 6 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4451 Serial Data Communication Enable Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4452 Accessory Wakeup Serial Data and Local Interconnect Network Bus Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4453 Powertrain Expansion Bus (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4454 Serial Data Gateway (SDG) Module (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4455 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 4456 Information Bus: Description and Operation Data Link Communications Description and Operation Circuit Description The communication among control modules is performed through the high speed GMLAN serial data circuits and the low speed GMLAN serial data circuit. The modules that need real time communication are attached to the High Speed GMLAN network. The body control module (BCM) is the gateway between the high and low speed networks. Refer to Body Control System Description and Operation (See: Body and Frame/Body Control Systems/Description and Operation) for more information about the gateway. Signal supervision is the process of determining whether an expected signal is being received or not. Some messages are sent on a periodic basis and are interpreted as a heartbeat of a device. If such a signal is lost, the signal supervision part of the software will set a no communication DTC (U. code) against the missing device. This code is mapped on the Tech 2 screen as a code against the physical device. A lost communication DTC typically is set in modules other than the module with a communication failure. GMLAN High Speed Circuit Description The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit. The serial data is transmitted on 2 twisted wires that allow speed up to 500 Kb/s. The twisted pair is terminated with two 120-ohm resistors, one is internal to the engine control module (ECM) and the other is after the electronic brake control module (EBCM), or if equipped, the suspension control module. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level, which is approximately 2.5 volts, is considered recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes, adds 1 volt to the high speed GMLAN serial data bus (+) and subtracts 1 volt from the high speed GMLAN serial data bus (-) wire. If a communication signal is lost, the application will set a no communication code against the respective control module. This code is mapped on the Tech 2 screen as a code against the physical device. Note: a loss of serial data DTC does not represent a failure of the module that the code is set in. The high speed GMLAN serial data allows communication between the body control module (BCM), ECM, transmission control module (TCM), vehicle communication interface module (VCIM), 4WD control module, EBCM, and the suspension control module depending on RPO. GMLAN Low Speed Circuit Description The data link connector (DLC) allows a scan tool to communicate with the low speed GMLAN serial data circuit. The serial data is transmitted over a single wire to the appropriate control modules. Under normal vehicle operating conditions, the speed of the buss is 33.33 Kb/s. This protocol produces a simple pulse train sent out over the GMLAN low speed serial data bus. When a module pulls the buss high, 5 volts, this creates a logic state of 0 on the buss. When the buss is pulled low, 0 volts, it is translated as a logic state of 1. To wake the control modules connected to the GMLAN low speed serial data buss, a wake up signal is sent out over the buss. Modules connected to the GMLAN low speed buss can be part of a virtual network as described in GMLAN High Speed Circuit Description above. The modules on the GMLAN low speed serial data buss are connected to the buss using several splice or "star" connectors separating groups of modules. The following lists state the splices and modules connected to the low speed serial data circuits: I/P Splice * Data link connector (DLC), connected only to the instrument panel (I/P) splice * Amplifier (Amp) * Rear seat audio (RSA) * Vehicle communication interface module (VCIM) * Digital radio receiver (DRR) * Inside rearview mirror module (ISRVM), connected through the mid I/P fuse block * Instrument panel cluster (IPC) * Body control module (BCM) * Theft deterrent module (TDM) * Heater ventilation and air conditioning (HVAC) * Radio * Driver door switch (DDS), connected through the left I/P fuse block * Passenger door switch (PDS), connected through the right I/P fuse block Body Splice * Articulating running board module (ARBM) * Ultrasonic park assist (UPA) * Memory seat module (MSM) * Liftgate module (LGM) * Passenger presence system (PPS) * Inflatable restraint vehicle rollover sensor (ROS) * Inflatable restraint sensing and diagnostic module (SDM) Data Link Connector (DLC) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 4457 The data link connector (DLC) is a standardized 16-cavity connector. The DLC low speed serial data circuit is connected directly to the instrument panel (I/P) splice then to all other splices or modules. Connector design and location is dictated by an industry wide standard, and is required to provide the following: * Pin 1 GMLAN low speed communications terminal * Pin 4 scan tool power ground terminal * Pin 5 common signal ground terminal * Pin 6 high speed GMLAN serial data bus (+) terminal * Pin 14 high speed GMLAN serial data bus (-) terminal * Pin 16 scan tool power, battery positive voltage terminal Serial Data Reference The scan tool communicates over the various busses on the vehicle. When a scan tool is installed on a vehicle, the scan tool will try to communicate with every module that could be optioned into the vehicle. If an option is not installed on the vehicle, the scan tool will display No COMM for that options specific control module. In order to avert misdiagnoses of No Communication with a specific module, refer to Data Link References (See: Testing and Inspection/Initial Inspection and Diagnostic Overview) for a list of modules, the busses they communicate with, and the RPO codes for a specific module. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Data Link References This table identifies which serial data link that a particular module uses for in-vehicle data transmission. Some modules may use more than one data link to communicate. Some modules may have multiple communication circuits passing through them without actively communicating on that data link. This table is used to assist in correcting a communication malfunction. For the description and operation of these serial data communication circuits refer to Data Link Communications Description and Operation (See: Description and Operation). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4460 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4461 Information Bus: Symptom Related Diagnostic Procedures Symptoms - Data Communications Symptoms - Data Communications Note: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) before using the symptom tables in order to verify that all of the following are true: * There are no DTCs set. * The control modules can communicate via the serial data links. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Data Link Communications Description and Operation (See: Description and Operation). Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the systems. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Scan Tool Does Not Power Up (See: Scan Tool Does Not Power Up) * Scan Tool Does Not Communicate with High Speed GMLAN Device (See: Scan Tool Does Not Communicate with High Speed GMLAN Device) * Scan Tool Does Not Communicate with Low Speed GMLAN Device (See: Scan Tool Does Not Communicate with Low Speed GMLAN Device ) * Scan Tool Does Not Communicate with Powertrain High Speed GMLAN Device (See: Scan Tool Does Not Communicate with Powertrain High Speed GMLAN Device) Scan Tool Does Not Communicate with High Speed GMLAN Device Scan Tool Does Not Communicate with High Speed GMLAN Device Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4462 Circuit/System Description The serial data is transmitted on two twisted wires that allow speeds up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the engine control module (ECM) and the other can be a separate resistor in a connector assembly or in another control module. The resistors are used as the load for the High Speed GMLAN buss during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level of approximately 2.5 V. Driving the lines to their extremes, adds one volt to the high speed GMLAN serial data bus (+) circuit and subtracts one volt from the high speed GMLAN serial data bus (-) circuit. If serial data is lost, control modules will set a no communication code against the non-communicating control module. Note that a loss of serial data DTC does not represent a failure of the module that set it. Diagnostic Aids * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-of-communication U-codes such as these can set for a variety of reasons. Many times, they are transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: - A control module on the data communication circuit was disconnected while the communication circuit is awake. - Power to one or more modules was interrupted during diagnosis - A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. - Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. - If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U-code. The U-code identifies which control module needs to be diagnosed for a communication issue. * Communication may be available between the BCM and the scan tool with the high speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. When the scan tool attempts to communicate with the vehicle a message "no CANdi module detected" will be displayed. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed GMLAN communications with the scan tool. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: - Vehicle will not crank. - Vehicle cranks but will not start. - Vehicle stability enhancement system warning lights and messages. - PRNDL gear indicator position errors. - Tire Pressure Monitor (TPM) system warning lights. Reference Information Schematic Reference * Data Communication Schematics (See: Diagrams/Electrical Diagrams) * Control Module References (See: Testing and Inspection/Programming and Relearning) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4463 Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Testing Note: Each control module may need to be disconnected to isolate a circuit fault. Use the schematic to identify the following: * Control modules the vehicle is equipped with * High speed GMLAN serial data circuit terminating resistors * Control module locations on the high speed GMLAN serial data circuits * Each control module's high speed GMLAN serial data circuit terminals 1. Attempt to communicate with all control modules on the high speed GMLAN serial data circuit, refer to Data Link References (See: Initial Inspection and Diagnostic Overview). Communications should not be available with two or more control modules on the high speed GMLAN serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only; refer to DTC U0100-U02FF (with HP2) (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100)DTC U0100-U02FF (without HP2) (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100). 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 4. Ignition ON, test for less than 4.5 V between the serial data circuits listed below and ground: * Terminal 6 * Terminal 14 ‹› If greater than the specified range, test the serial data circuit for a short to voltage; refer to Testing the Serial Data Circuits for a Short to Voltage. 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuits listed below and ground: * Terminal 6 * Terminal 14 ‹› If not the specified value, test the serial data circuit for a short to ground; refer to Testing the Serial Data Circuits for a Short to ground. 6. Test for 50-70 ohm between the serial data circuits terminal 6 and terminal 14. ‹› If less than 35 ohm, test for a short between the serial data circuits; refer to Testing the Serial Data Circuits for a Short between the Circuits. ‹› If 35-50 ohm there may be a third terminating resistor between the serial data circuits. This can happen if the incorrect control module is installed. Some control modules are available with and without the terminating resistors installed to reduce the need of terminating resistors in the wiring harness. ‹› If greater than 70 ohm but less than infinite, test the serial data circuit for an open/high resistance; refer to Testing the Serial Data Circuits for an Open/High Resistance. ‹› If infinite, test the serial data circuits between the DLC and the first connection to the serial data circuit for an open/high resistance. Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4464 2. Ignition ON, test for greater than 4.5 V between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was disconnected. 3. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to voltage. 4. Ignition ON, test for greater than 4.5 V between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to voltage on the serial data circuit between 2 control modules * A short to voltage on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition OFF for 60 seconds, test for less than 1k ohm between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If all serial data circuits are greater than the specified range, replace the control module that was disconnected. 3. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to ground. 4. Ignition OFF for 60 seconds, test for less than 1k ohm between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If greater than the specified range for all serial data circuits, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to ground on the serial data circuit between 2 control modules * A short to ground on the serial data circuit between a control module and a terminating resistor Testing the Serial Data Circuits for a Short between the Circuits 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is greater than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuits shorted together. 5. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is within the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * Serial data circuits shorted together between 2 control modules * Serial data circuits shorted together between a control module and a terminating resistor * A shorted terminating resistor Testing the Serial Data Circuits for an Open/High Resistance 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was disconnected. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4465 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the open circuit. 5. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * An open/high resistance on the serial data circuit between 2 control modules * An open/high resistance on the serial data circuit between a control module and a terminating resistor * An open/high resistance terminating resistor Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * Control Module References (See: Testing and Inspection/Programming and Relearning) for control module replacement, setup, and programming Scan Tool Does Not Communicate with Low Speed GMLAN Device Scan Tool Does Not Communicate with Low Speed GMLAN Device Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description Modules connected to the low speed GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules when the ignition switch is in any position other than OFF. The low speed GMLAN serial data circuit uses JX 221, JX 339, and, if equipped, JX 223 as common connection points between some modules and the data link connector (DLC). Diagnostic Aids * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-of-communication U-codes such as these can set for a variety of reasons. Many times, they are transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: - A control module on the data communication circuit was disconnected while the communication circuit is awake. - Power to one or more modules was interrupted during diagnosis - A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. - Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4466 - If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U-code. The U-code identifies which control module needs to be diagnosed for a communication issue. * Communication may be available between the BCM and the scan tool with the high speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. When the scan tool attempts to communicate with the vehicle a message "no CANdi module detected" will be displayed. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed GMLAN communications with the scan tool. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: - Vehicle will not crank. - Vehicle cranks but will not start. - Vehicle stability enhancement system warning lights and messages. - PRNDL gear indicator position errors. - Tire Pressure Monitor (TPM) system warning lights. Reference Information Schematic Reference Data Communication Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference * Component Connector End Views (See: Diagrams/Connector Views) * Splice Pack Connector End Views (See: Diagrams/Connector Views/Splices By Number) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Circuit/System Testing Note: Use the schematic to identify the following: * Control modules the vehicle is equipped with * Control module locations on the low speed GMLAN serial data circuit * Each control module's low speed GMLAN serial data circuit terminals 1. Attempt to communicate with all control modules on the low speed GMLAN serial data circuit, refer to Data Link References (See: Initial Inspection and Diagnostic Overview). Communications should not be available with two or more control modules on the low speed GMLAN serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only, refer to DTC U0100-U02FF (with HP2) (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100)DTC U0100-U02FF (without HP2) (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100). ‹› If one or more control modules are communicating but not all, refer to Testing the Serial Data Circuit for an Open/High Resistance. 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4467 4. Ignition ON, test for less than 4.5 V between the serial data circuit terminal 1 and ground. ‹› If greater than the specified range, test the serial data circuit for a short to voltage, refer to Testing the Serial Data Circuit for a Short to Voltage. 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuit terminal 1 and ground. ‹› If not the specified value, test the serial data circuit for a short to ground, refer to Testing the Serial Data Circuits for a Short to ground. 6. Disconnect the harness connector at the JX 221 splice pack. 7. Test for less than 2 ohm between the serial data circuit terminal 1 and the JX 221 splice pack terminal D. ‹› If greater than the specified range, test the serial data circuit for an open/high resistance. If the circuits test normal, replace the splice pack. Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the harness connectors at the JX 221, JX 339, and JX 223 splice packs, as equipped. 2. Ignition ON, test for less than 4.5 V between the DLC serial data circuit terminal 1 and ground. ‹› If greater than the specified range, repair the short to voltage. 3. Test for less than 4.5 V between each serial data circuit and ground. ‹› If greater than the specified range, perform the appropriate test listed below: * Serial data circuits with one control module, test the serial data circuit for a short to voltage. If the circuit tests normal replace the control module. * Serial data circuits with 2 or more control modules, test each section of the serial data circuit for a short to voltage. If the circuits test normal, replace the control module that causes the short to voltage when connected. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the harness connectors at the JX 221, JX 339, and JX 223 splice packs, as equipped. 2. Test for infinite resistance between the DLC serial data circuit terminal 1 and ground. ‹› If not the specified value, repair the short to ground. 3. Ignition OFF for 60 seconds, test for greater than 100 ohm between each serial data circuit and ground. ‹› If less than the specified range, perform the appropriate test listed below: * Serial data circuits with one control module, test the serial data circuit for a short to ground. If the circuit tests normal replace the control module. * Serial data circuits with 2 or more control modules, test each section of the serial data circuit for a short to ground. If the circuits test normal, replace the control module that causes the short to ground when connected. Testing the Serial Data Circuit for an Open/High Resistance 1. If equipped with a JX 339 splice pack, ignition ON, verify the scan tool communicates with one or more control modules connected to the JX 339 splice pack. ‹› If all control modules on the JX 339 spice pack do not communicate, test the serial data circuit between the JX 221 and JX 339 splice packs for an open/high resistance. If the circuit tests normal, test each splice pack for an open/high resistance. 2. Ignition OFF, disconnect one of the harness connectors listed below: * JX 221 if the control modules not communicating are connected to the JX 221 splice pack * JX 223 if the control modules not communicating are connected to the JX 223 splice pack, if equipped * JX 339 if the control modules not communicating are connected to the JX 339 splice pack 3. Install a 3A fused jumper wire between the disconnected splice pack connector terminal listed below and a low speed GMLAN serial data circuit that is not communicating: * JX 221 terminal D * JX 223 terminal A * JX 339 terminal A 4. Ignition ON, verify the scan tool communicates with the control modules connected to the low speed GMLAN serial data circuit. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4468 ‹› If any control module does not communicate, test each section of the serial data circuit for an open/high resistance. If the circuits test normal, replace the control module that does not communicate when connected. Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * Control Module References (See: Testing and Inspection/Programming and Relearning) for module replacement, setup, and programming Scan Tool Does Not Power Up Scan Tool Does Not Power Up Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: * Scan tool B+ voltage at terminal 16 * Scan tool ground at terminal 4 * Common ground at terminal 5 Diagnostic Aids * The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. * If the B+ circuit, ground circuits, and connections of the DLC are functioning properly, the malfunction must be due to the scan tool/CANdi module. Reference Information Schematic Reference Data Communication Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4469 Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information. Circuit/System Testing 1. Test for less than 2.0 ohms between the ground circuits terminal 4 of the DLC and ground, and terminal 5 of the DLC and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 2. Ignition ON, verify a test lamp illuminates between the B+ circuit terminal 16 at the DLC and ground. ‹› If the test lamp does not illuminate, test the voltage supply circuit for a short to ground or an open/high resistance. 3. If all circuits test normal, refer to the scan tool/CANdi module user guide. Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. Scan Tool Does Not Communicate with Powertrain High Speed GMLAN Device Scan Tool Does Not Communicate with Powertrain High Speed GMLAN Device Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The serial data is transmitted on two twisted wires that allow speeds up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the engine control module (ECM) and the other can be a separate resistor in a connector assembly or in another control module. The resistors are used as the load for the Powertrain High Speed GMLAN buss during normal vehicle operation. The Powertrain High Speed GMLAN is a differential bus. The Powertrain High Speed GMLAN serial data bus (+) and Powertrain High Speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level of approximately 2.5 V. Driving the lines to their extremes, adds one volt to the Powertrain High Speed GMLAN serial data bus (+) circuit and subtracts one volt from the Powertrain High Speed GMLAN serial data bus (-) circuit. If serial data is lost, control modules will set a no communication code against the non-communicating control module. Note that a loss of serial data DTC does not represent a failure of the module that set it. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4470 Diagnostic Aids * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-ofcommunication U-codes such as these can set for a variety of reasons. Many times, they're transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: - A control module on the data communication circuit was disconnected while the communication circuit is awake. - Power to one or more modules was interrupted during diagnosis - A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. - Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. - If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U code. The U code identifies which control module needs to be diagnosed for a communication issue. * Communication may be available between the BCM and the scan tool with the Powertrain High Speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. When the scan tool attempts to communicate with the vehicle a message "no CANdi module detected" will be displayed. * The engine will not start when there is a total malfunction of the Powertrain High Speed GMLAN serial data bus. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed GMLAN communications with the scan tool. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: - Vehicle will not crank. - Vehicle cranks but will not start. - Vehicle stability enhancement system warning lights and messages. - PRNDL gear indicator position errors. - Tire Pressure Monitor (TPM) system warning lights. Reference Information Schematic Reference * Data Communication Schematics (See: Diagrams/Electrical Diagrams) * Control Module References (See: Testing and Inspection/Programming and Relearning) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Testing Note: Each control module may need to be disconnected to isolate a circuit fault. Use the schematic to identify the following: * Control modules the vehicle is equipped with Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4471 * Powertrain High Speed GMLAN serial data circuit terminating resistors * Control module locations on the Powertrain High Speed GMLAN serial data circuits * Each control module's Powertrain High Speed GMLAN serial data circuit terminals 1. Attempt to communicate with all control modules on the Powertrain High Speed GMLAN serial data circuit, refer to Data Link References (See: Initial Inspection and Diagnostic Overview). Communications should not be available with two or more control modules on the Powertrain High Speed GMLAN serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only; refer to DTC U0100-U02FF (with HP2) (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100)DTC U0100-U02FF (without HP2) (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100). 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 4. Ignition ON, test for less than 4.5 V between the serial data circuits listed below and ground: * Terminal 3 * Terminal 11 ‹› If greater than the specified range, test the serial data circuit for a short to voltage; refer to Testing the Serial Data Circuits for a Short to Voltage. 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuits listed below and ground: * Terminal 3 * Terminal 11 ‹› If not the specified value, test the serial data circuit for a short to ground; refer to Testing the Serial Data Circuits for a Short to ground. 6. Test for 50-70 ohm between the serial data circuits terminal 3 and terminal 11. ‹› If less than 35 ohm, test for a short between the serial data circuits; refer to Testing the Serial Data Circuits for a Short between the Circuits. ‹› If 35-50 ohm there may be a third terminating resistor between the serial data circuits. This can happen if the incorrect control module is installed. Some control modules are available with and without the terminating resistors installed to reduce the need of terminating resistors in the wiring harness. ‹› If greater than 70 ohm but less than infinite, test the serial data circuit for an open/high resistance; refer to Testing the Serial Data Circuits for an Open/High Resistance. ‹› If infinite, test the serial data circuits between the DLC and the first connection to the serial data circuit for an open/high resistance. Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition ON, test for greater than 4.5 V between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was disconnected. 3. Ignition OFF, disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to voltage. 4. Ignition ON, test for greater than 4.5 V between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to voltage on the serial data circuit between 2 control modules * A short to voltage on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition OFF for 60 seconds, test for less than 1k ohm between each serial data circuit at the control module connector that was just disconnected Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4472 and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If all serial data circuits are greater than the specified range, replace the control module that was disconnected. 3. Disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to ground. 4. Ignition OFF for 60 seconds, test for less than 1k ohm between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If greater than the specified range for all serial data circuits, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to ground on the serial data circuit between 2 control modules * A short to ground on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short between the Circuits 1. Ignition OFF, disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is greater than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at another control module, in the direction of the circuits shorted together. 5. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is within the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * Serial data circuits shorted together between 2 control modules * Serial data circuits shorted together between a control module and a terminating resistor * A shorted terminating resistor Testing the Serial Data Circuits for an Open/High Resistance 1. Ignition OFF, disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at another control module, in the direction of the open circuit. 5. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * An open/high resistance on the serial data circuit between 2 control modules * An open/high resistance on the serial data circuit between a control module and a terminating resistor * An open/high resistance terminating resistor Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4473 Procedures/Wiring Repairs/GMLAN Wiring Repairs) * Control Module References (See: Testing and Inspection/Programming and Relearning)for control module replacement, setup, and programming Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4477 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 4480 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (4) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 4481 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 4482 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (2) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4486 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4487 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4488 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4489 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4490 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4491 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4492 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. Reference Information Schematic Reference * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges and Warning Indicators/System Diagram/Instrument Cluster Schematics) * Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 2. Ignition ON, verify that a test lamp illuminates between the ignition circuit and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC. 3. Connect a test lamp between the control circuit and the ignition circuit. 4. Command the MIL ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, replace the IPC. Repair Instructions Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Page 4496 Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Instrument Cluster Replacement (Without RPO SLT) (See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (Without RPO SLT))Instrument Cluster Replacement (With RPO SLT) (See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (With RPO SLT)) * Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM replacement, setup, and programming Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (LU3) Manifold Absolute Pressure (MAP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4500 Manifold Absolute Pressure (MAP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4501 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4502 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (4) from the manifold absolute pressure (MAP) sensor. 3. Remove the MAP sensor retainer. 4. Remove the MAP sensor. Installation Procedure Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4503 1. Install the MAP sensor. 2. Install the MAP sensor retainer. 3. Connect the engine harness wiring electrical connector (4) to the MAP sensor. 4. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 4507 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 4508 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 4509 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 4510 washer (707). 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 4511 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Harness Routing Views Heated Oxygen Sensor (HO2S) Jumper Harness Routing (LY6) 1 - X125 2 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4515 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LU3) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (Gas except LU3 and except ZW9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4516 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY6 or L96 with ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4517 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (Gas except LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4518 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (Gas except LU3 and except ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY6 or L96 with ZW9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4519 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4520 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 4523 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 4524 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 4525 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Unbolt the front propeller shaft from the front differential, if equipped with four wheel drive (4WD). Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 3. For vehicles equipped with a 4L60-E/4L70-E automatic transmission perform the following steps, for vehicles equipped with a 6L80-E automatic transmission proceed to step 7. 4. Remove the connector position assurance (CPA) retainer. 5. Disconnect the engine wiring harness electrical connector (2) from the HO2S. 6. Remove the HO2S electrical connector clip (1) from the fuel line clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4528 7. Remove the CPA retainer (2). 8. Remove the engine wiring harness electrical connector clip (1) from the fuel line clip. 9. Disconnect the engine wiring harness electrical connector (3) from the HO2S. Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 10. Remove the HO2S (1 or 2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4529 Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 2. Install the HO2S (1 or 2). Tighten the sensor to 42 Nm (31 lb ft). 3. For vehicles equipped with a 4L60-E/4L70-E automatic transmission perform the following steps, for vehicles equipped with a 6L80-E automatic transmission proceed to step 7. 4. Install the HO2S electrical connector clip (1) to the fuel line clip. 5. Connect the engine wiring harness electrical connector (2) to the HO2S. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4530 6. Install the CPA retainer. 7. Connect the engine wiring harness electrical connector (3) to the HO2S. 8. Install the engine wiring harness electrical connector clip (1) to the fuel line clip. 9. Install the CPA retainer (2). 10. Install the front propeller shaft to the front differential, if equipped with 4WD. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 11. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4531 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the connector position assurance (CPA) retainer (1). 3. Disconnect the HO2S electrical connector from the engine wiring harness electrical connector (3). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 4. Remove the HO2S (5). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4532 Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 2. Install the HO2S (5). Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the HO2S electrical connector to the engine wiring harness electrical connector (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4533 4. Install the CPA retainer (1). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4534 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) 1. Remove the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 2. Remove the connector position assurance (CPA) retainer (2). 3. Disconnect the HO2S electrical connector (7) from the engine wiring harness electrical connector (1). 4. Remove the HO2S clip (8) from the engine wiring harness. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4535 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) 5. Remove the HO2S (3). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution) 2. Install the HO2S (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4536 Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the HO2S electrical connector (7) to the engine wiring harness electrical connector (1). 4. Install the CPA retainer (2). 5. Install the HO2S clip (8) to the engine wiring harness. 6. Install the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4537 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the connector position assurance (CPA) retainer (5). 3. Disconnect the engine wiring harness electrical connector (4) from the HO2S electrical connector (3). 4. Remove the HO2S electrical connector clip from the engine harness clip (6). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4538 5. Remove the HO2S (4). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution) 2. Install the HO2S (4). Tighten the sensor to 42 Nm (31 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4539 3. Install the HO2S electrical connector clip to the engine harness clip (6). 4. Connect the engine wiring harness electrical connector (4) to the HO2S electrical connector (3). 5. Install the CPA retainer (5). 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 4558 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 4564 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4565 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4566 Body Control Module (BCM) X2 Body Control Module (BCM) X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4567 Body Control Module (BCM) X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4568 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4569 Body Control Module (BCM) X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4570 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4571 Body Control Module (BCM) X6 Body Control Module (BCM) X7 (except MEX or A52) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4572 Auxiliary Body Control Module (XBCM) X1 (EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4573 Auxiliary Body Control Module (XBCM) X2 (EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4574 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 4577 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 4578 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 4579 Body Control Module: Service and Repair Serial Data Gateway Module Replacement Serial Data Gateway Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 4593 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4598 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4599 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4600 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4609 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4610 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4611 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 4617 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4622 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4623 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4624 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4629 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4630 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 4631 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4632 Engine Control Module: Locations Harness Routing Views Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4633 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Engine Harness Routing - Top (4.3L) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4634 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4635 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4636 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4637 Engine Control Module (ECM) X1 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4638 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4639 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4640 Engine Control Module (ECM) X1 (LY2, LMG, LC9, LY5, LH6, L76 or L9H) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4641 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4642 Engine Control Module (ECM) X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4643 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4644 Engine Control Module (ECM) X1 (LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4645 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4646 Engine Control Module (ECM) X2 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4647 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4648 Engine Control Module (ECM) X2 (LY2, LY6 or L9H with Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4649 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4650 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4651 Engine Control Module (ECM) X2 (LMG, LC9, LY5, LH6, L76 or L9H without Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4652 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4653 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4654 Engine Control Module (ECM) X2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4655 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4656 Engine Control Module (ECM) X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4657 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4658 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4659 Engine Control Module (ECM) X3 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4660 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4661 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4662 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4663 Engine Control Module: Service and Repair Engine Control Module Replacement Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: Record the current Engine Oil Life percentage, and use a scan tool to update the NEW ECM, if replacing. Removal Procedure 1. Record the current Engine Oil Life percentage, and use a scan tool to update the NEW ECM, if replacing. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Disengage the engine wiring harness upper electrical connector retainer (2) and remove the connector (1) from the ECM. 4. Disengage the engine wiring harness lower electrical connector retainer (3) and remove the connector (4) from the ECM. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4664 5. Disengage the retainer tabs securing the ECM to the bracket. 6. Remove the ECM. Installation Procedure 1. Install the bottom ECM tabs into the bracket. 2. Push the ECM in securing the ECM to the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4665 3. Position the engine wiring harness lower electrical connector and engage the retainer (3) securing the lower connector (4) to the ECM. 4. Position the engine wiring harness upper electrical connector and engage the retainer (2) securing the upper connector (1) to the ECM. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 6. If a NEW ECM was installed, program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4669 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4670 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4671 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4672 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4673 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4674 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4675 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4680 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4681 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 2. Remove the accelerator pedal bolts. 3. Remove the accelerator pedal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4682 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4686 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4687 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4688 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4689 Installation Procedure Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the MAF/IAT sensor adapter clamp. Tighten the clamp to 4 Nm (35 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 4693 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 4694 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4698 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4699 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4700 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4701 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4702 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4703 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement (Except RPOs LY2, LY5, LH6 and LMG) Removal Procedure Note: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the CMP sensor wire harness. 3. Remove the 3 CMP sensor wire harness bolts (738). 4. Disconnect the CMP sensor wire harness electrical connectors from the CMP sensor and the CMP actuator magnet. 5. Remove the CMP sensor wire harness (737). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4704 6. Remove the CMP sensor (703) and O-ring seal (704). Installation Procedure 1. Inspect the CMP O-ring seal for cuts or damage. If the seal is not cut or damaged, it may be used again. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal (704) onto the sensor. 4. Instal the CMP sensor (703) to the front cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4705 5. Install the CMP sensor wire harness (737). 6. Connect the CMP sensor wire harness electrical connectors to the CMP sensor and the CMP actuator magnet. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the 3 CMP sensor wire harness bolts (738). Tighten the bolts to 12 Nm (106 lb in). 8. Connect the engine wiring harness electrical connector (1) to the CMP sensor wire harness. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Clutch Switch: Diagrams Component Connector End Views Clutch Pedal Position (CPP) Switch (TZ0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4717 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4718 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4719 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4720 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4726 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4727 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4728 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4729 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4730 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4731 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor. 3. Remove the ECT sensor. Installation Procedure Caution: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4732 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ECT sensor and tighten to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor. 4. Refill the cooling. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4736 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4737 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4738 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The Crankshaft Position System Variation Learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * An engine replacement * A engine control module (ECM) replacement * A crankshaft balancer replacement * A crankshaft replacement * A crankshaft position sensor replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The ECM monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position System Variation Learn Procedure. 1. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 2. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 3. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 4. Enable the CKP System Variation Learn Procedure with a scan tool. 5. Quickly apply and release the accelerator pedal. 6. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 7. The scan tool displays Learn Status: Learned this ignition. 8. Once the Learn Procedure has successfully completed, and in order to store the crankshaft position system variation values in the ECM, turn OFF the ignition and verify all vehicle systems are OFF. This may take up to 2 minutes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4739 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure Note: Perform the Crankshaft Position System Variation Learn (See: Testing and Inspection) whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4740 5. Remove the CKP sensor. Installation Procedure 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4745 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4746 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) ( See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4747 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Reg Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Reg Cab With 26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4748 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4749 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) ( See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4750 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 gal Tank) Fuel Level Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 gal Tnk) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4751 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4752 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) ( See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 Gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4758 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4759 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 REG Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Reg Cab With 26 Gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4760 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4761 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15/25 REG/Ext/Crw Cab With 34 gal Tank) Fuel Tank Pressure Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) > Page 4762 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Page 4766 Installation Procedure Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the MAF/IAT sensor adapter clamp. Tighten the clamp to 4 Nm (35 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4770 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 4773 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (4) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 4774 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 4775 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (2) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (LU3) Manifold Absolute Pressure (MAP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4779 Manifold Absolute Pressure (MAP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4780 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4781 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (4) from the manifold absolute pressure (MAP) sensor. 3. Remove the MAP sensor retainer. 4. Remove the MAP sensor. Installation Procedure Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4782 1. Install the MAP sensor. 2. Install the MAP sensor retainer. 3. Connect the engine harness wiring electrical connector (4) to the MAP sensor. 4. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 4786 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 4787 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 4788 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. If not equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 4789 washer (707). 4. If equipped with active fuel management perform the following step, using J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If equipped with active fuel management perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 4790 3. If not equipped with active fuel management, perform the following step, using J 41712 or equivalent. Install the oil pressure sensor (706) and washer (707). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 5. Install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Harness Routing Views Heated Oxygen Sensor (HO2S) Jumper Harness Routing (LY6) 1 - X125 2 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4794 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LU3) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (Gas except LU3 and except ZW9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4795 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY6 or L96 with ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4796 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (Gas except LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4797 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (Gas except LU3 and except ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY6 or L96 with ZW9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4798 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4799 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 4802 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 4803 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 4804 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Unbolt the front propeller shaft from the front differential, if equipped with four wheel drive (4WD). Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 3. For vehicles equipped with a 4L60-E/4L70-E automatic transmission perform the following steps, for vehicles equipped with a 6L80-E automatic transmission proceed to step 7. 4. Remove the connector position assurance (CPA) retainer. 5. Disconnect the engine wiring harness electrical connector (2) from the HO2S. 6. Remove the HO2S electrical connector clip (1) from the fuel line clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4807 7. Remove the CPA retainer (2). 8. Remove the engine wiring harness electrical connector clip (1) from the fuel line clip. 9. Disconnect the engine wiring harness electrical connector (3) from the HO2S. Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 10. Remove the HO2S (1 or 2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4808 Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 2. Install the HO2S (1 or 2). Tighten the sensor to 42 Nm (31 lb ft). 3. For vehicles equipped with a 4L60-E/4L70-E automatic transmission perform the following steps, for vehicles equipped with a 6L80-E automatic transmission proceed to step 7. 4. Install the HO2S electrical connector clip (1) to the fuel line clip. 5. Connect the engine wiring harness electrical connector (2) to the HO2S. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4809 6. Install the CPA retainer. 7. Connect the engine wiring harness electrical connector (3) to the HO2S. 8. Install the engine wiring harness electrical connector clip (1) to the fuel line clip. 9. Install the CPA retainer (2). 10. Install the front propeller shaft to the front differential, if equipped with 4WD. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 11. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4810 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the connector position assurance (CPA) retainer (1). 3. Disconnect the HO2S electrical connector from the engine wiring harness electrical connector (3). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution). 4. Remove the HO2S (5). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4811 Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 2. Install the HO2S (5). Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the HO2S electrical connector to the engine wiring harness electrical connector (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4812 4. Install the CPA retainer (1). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4813 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) 1. Remove the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 2. Remove the connector position assurance (CPA) retainer (2). 3. Disconnect the HO2S electrical connector (7) from the engine wiring harness electrical connector (1). 4. Remove the HO2S clip (8) from the engine wiring harness. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4814 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) 5. Remove the HO2S (3). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution) 2. Install the HO2S (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4815 Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the HO2S electrical connector (7) to the engine wiring harness electrical connector (1). 4. Install the CPA retainer (2). 5. Install the HO2S clip (8) to the engine wiring harness. 6. Install the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4816 Oxygen Sensor: Service and Repair Heated Oxygen Sensor - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (1500 Series) Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the connector position assurance (CPA) retainer (5). 3. Disconnect the engine wiring harness electrical connector (4) from the HO2S electrical connector (3). 4. Remove the HO2S electrical connector clip from the engine harness clip (6). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4817 5. Remove the HO2S (4). Installation Procedure Note: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution) 2. Install the HO2S (4). Tighten the sensor to 42 Nm (31 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor - Bank 1 Sensor 1 > Page 4818 3. Install the HO2S electrical connector clip to the engine harness clip (6). 4. Connect the engine wiring harness electrical connector (4) to the HO2S electrical connector (3). 5. Install the CPA retainer (5). 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Parking Lock and Manual Shift Detent Lever with Shaft Position Switch Assembly 78 - Steel Cup Plug 79 - Parking Brake Pawl Shaft 80 - Parking Pawl Return Spring 81 - Parking Brake Pawl 82 - Manual Shaft Seal 84 - Manual Shaft - Model Dependent 85 - Parking Lock Actuator Assembly 86 - Parking Lock Bracket 87 - Parking Lock Bracket Bolt 88 - Manual Shift Detent Lever with Shaft Position Switch Assembly 89 - Manual Valve Link 92 - Manual Shift Detent Lever Hub Pin Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4823 Transmission Position Switch/Sensor: Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4824 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4827 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4828 Transmission Position Switch/Sensor: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 Nm (9 lb ft). 3. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Install the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4829 Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations Vehicle Speed Sensor: Component Locations Disassembled Views Case and Associated Parts (1 of 2) 1 - Torque Converter Assembly - Size Model Dependent 2 - Pump to Case Bolt 3 - Pump to Case Bolt O-Ring 4 - Oil Pump Assembly 5 - A/T Fluid Pump Seal - Pump to Case 6 - Pump Cover to Case Gasket 7 - Case Bushing 9 - Transmission Vent Assembly 11 - Case Servo Plug 12 - Servo Return Spring 13 - 2nd Apply Piston Pin 14 - Retainer Ring - 2nd Apply Piston 15 - Servo Cushion Spring Retainer 16 - Servo Cushion Spring - Outer 17 - 2nd Apply Piston 18 - Oil Seal Ring - 2nd Apply Piston - Outer 19 - Oil Seal Ring - 2nd Apply Piston - Inner Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 4834 20 - Servo Piston Housing - Inner 21 - O-Ring Seal 22 - Servo Apply Pin Spring 23 - Servo Apply Pin Washer 24 - Retainer Ring - Apply Pin 25 - 4th Apply Piston 26 - Oil Seal Ring - 4th Apply Piston - Outer 27 - O-Ring Seal - 2-4 Servo Cover 28 - 2-4 Servo Cover 29 - Servo Cover Retaining Ring 30 - Case Extension to Case Seal 31 - Case Extension - Model Dependent 32 Case Extension to Case Bolt 33 - Case Extension Bushing 34 - Case Extension Oil Seal Assembly - Model Dependent 34 - Case Extension Oil Seal Assembly - Model Dependent 35 - Speed Sensor Retaining Bolt 36 - Vehicle Speed Sensor (VSS) 37 - O-Ring Seal - VSS to Case Extension 71 Filter Seal 72 - Transmission Oil Filter Assembly - Model Dependent 73 - Transmission Oil Pan Gasket 74 - Chip Collector Magnet 75 - Transmission Oil Pan - Model Dependent 76 Transmission Oil Pan Screw 94 - Converter Housing to Case Bolt 95 - Oil Cooler Quick Connector 96 - Oil Cooler Quick Connect Clip 97 - Converter Housing Access Hole Plug - Model Dependent 98 - Converter Bolt Inspection Plate - Model Dependent 99 - Cup D4 Orifice Plug 102 - Converter Housing - Model Dependent 103 - Main Section Case - Model Dependent 105 - Servo Cushion Spring - Inner - Model Dependent Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 4835 Vehicle Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 4836 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) (M30, TZ0, MYC and MW7or M99 with NQG or NQF) Vehicle Speed Sensor (VSS) (MW7 except NQG or NQF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 4837 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the VSS bolt (2). Tighten the bolt to 11 Nm (97 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4840 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4841 Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4842 Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4843 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the VSS and O-ring seal. Tighten the VSS to 16 Nm (12 lb ft). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4844 Vehicle Speed Sensor: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4845 Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the VSS bolt (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4846 Tighten the bolt to 11 Nm (97 lb in). 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4847 Tremec 5-Speed (TZ0) - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4848 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the VSS and O-ring seal. Tighten the VSS to 16 Nm (12 lb ft). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4849 MP 1625/1626-NQF - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4850 MP 3023/3024-NQH - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4851 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Parking Lock and Manual Shift Detent Lever with Shaft Position Switch Assembly 78 - Steel Cup Plug 79 - Parking Brake Pawl Shaft 80 - Parking Pawl Return Spring 81 - Parking Brake Pawl 82 - Manual Shaft Seal 84 - Manual Shaft - Model Dependent 85 - Parking Lock Actuator Assembly 86 - Parking Lock Bracket 87 - Parking Lock Bracket Bolt 88 - Manual Shift Detent Lever with Shaft Position Switch Assembly 89 - Manual Valve Link 92 - Manual Shift Detent Lever Hub Pin Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4856 Transmission Position Switch/Sensor: Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4857 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4860 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4861 Transmission Position Switch/Sensor: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 Nm (9 lb ft). 3. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Install the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4862 Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Diagrams Valve Deactivation Solenoid: Diagrams Component Connector End Views Valve Lifter Oil Manifold (VLOM) Assembly (LMG, LC9, LZ1 or L96) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Diagrams > Page 4866 Valve Deactivation Solenoid: Description and Operation Cylinder Deactivation (Active Fuel Management) System Description To provide maximum fuel economy under light load driving conditions, the engine control module (ECM) will command the cylinder deactivation system ON to deactivate engine cylinders 1, 7, 6, and 4, switching to a V4 mode. The engine will operate on 8 cylinders, or V8 mode, during engine starting, engine idling, and medium to heavy throttle applications. When cylinder deactivation is commanded, the ECM will determine what cylinder is firing and begin deactivation on the next closest deactivated cylinder in firing order sequence. For example, if cylinder number 1 is on its combustion event when cylinder deactivation is commanded ON, the next cylinder in the firing order sequence that can be deactivated is cylinder number 7. If cylinder number 5 is on its combustion event when cylinder deactivation is commanded ON, then the next cylinder in the firing order sequence that can be deactivated is cylinder number 4. Cylinder deactivation is accomplished by not allowing the intake and exhaust valves to open on the selected cylinders by using special valve lifters. The deactivation lifters contain spring loaded locking pins that connect the internal pin housing of the lifter to the outer housing. The pin housing contains the lifter plunger and pushrod seat which interfaces with the pushrod. The outer housing contacts the camshaft lobe through a roller. During V8 mode, when all cylinders are active, the locking pins are pushed outward by spring force, locking the pin housing and outer housing together causing the lifter to function as a normal lifter. When cylinder deactivation is commanded ON, the locking pins are pushed inward with engine oil pressure directed from the valve lifter oil manifold (VLOM) assembly solenoids. When the lifter pin housing is unlocked from the outer housing, the pin housing will remain stationary, while the outer housing will move with the profile of the camshaft lobe, which results in the valve remaining closed. One VLOM solenoid controls both the intake and exhaust valves for each deactivating cylinder. There are 2 distinct oil passages going to each cylinder deactivation lifter bore, one for the hydraulic lash-adjusting feature of the lifter, and one for controlling the locking pins used for cylinder deactivation. Although both intake and exhaust valve lifters are controlled by the same solenoid in the VLOM, the intake and exhaust valves do not become deactivated at the same time. Cylinder deactivation is timed so that the cylinder is on an intake event. During an intake event, the intake cam lobe is pushing the valve lifter upwards to open the intake valve against the force of the valve spring. The force exerted by the valve spring is acting on the side of the lifter locking pins, preventing them from moving until the intake valve has closed. When the intake valve lifter reaches the base circle of the camshaft lobe, the valve spring force is reduced, allowing the locking pins to move, deactivating the intake valve. However, when cylinder deactivation is commanded ON, the exhaust valve for the deactivated cylinder is in the closed position, allowing the locking pins on the valve lifter to move immediately, and deactivate the exhaust valve. By deactivating the exhaust valve first, this allows the capture of a burnt air/fuel charge, or exhaust gas charge, in the combustion chamber. The capture Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Diagrams > Page 4867 of exhaust gases in the combustion chamber will contribute to a reduction in oil consumption, noise and vibration levels, and exhaust emissions when operating in V4 mode cylinder deactivation mode. During the transition from V8 to V4 mode, the fuel injectors will be turned OFF on the deactivated cylinders. To help prevent spark plug fouling, the ignition system secondary voltage or spark is still present across the spark plug electrodes on the deactivated cylinders. If all enabling conditions are met and maintained for cylinder deactivation operation, the ECM calibrations will limit cylinder deactivation to a cycle time of 10 minutes in V4 mode, then return to V8 mode for 1 minute. Switching between V8 and V4 modes is accomplished in less than 250 milliseconds, making the transitions seamless and transparent to the vehicle operator. The 250 milliseconds includes the time for the ECM to sequence the transitions, the response time for the VLOM solenoids to energize, and the time for the valve lifters to deactivate, all within 2 revolutions of the engine crankshaft. Valve Lifter Oil Manifold (VLOM) Assembly The cylinder deactivation system uses an electro-hydraulic actuator device called the valve lifter oil manifold (VLOM) assembly. The VLOM is bolted to the top of the engine valley, below the intake manifold assembly. The VLOM consists of 4 electrically operated normally closed solenoids. Each solenoid controls the application of engine oil pressure to the intake and exhaust valve lifters on the cylinders selected to deactivate. Engine oil pressure is routed to the VLOM assembly from an internal oil passage on the rear of the cylinder block. All 4 VLOM solenoids are connected in parallel to a fused ignition 1 voltage circuit, supplied by the powertrain relay. The ground or control circuit for each solenoid is connected to a low side driver internal to the engine control module (ECM). When all enabling conditions are met for cylinder deactivation, the ECM will ground each solenoid control circuit in firing order sequence, allowing current to flow through the solenoid windings. With the coil windings energized, the solenoid valve opens, redirecting engine oil pressure through the VLOM into 8 separate vertical passages in the engine lifter valley. The 8 vertical passages, 2 per cylinder, are connected to the valve lifter bores of the cylinders to be deactivated. When vehicle-operating conditions require a return to V8 mode, the ECM will turn OFF the control circuit for the solenoids, allowing the solenoid valves to close. With the solenoid valves closed, engine oil pressure in the control ports is exhausted through the body of the solenoids into the engine block lifter valley. The housing of the VLOM incorporates several bleeds in the oil passages to purge any air trapped in the VLOM or engine block. To help control contamination to the hydraulic circuits, a small replaceable oil screen is located in the VLOM oil inlet passage, below the oil pressure sensor. The oil pressure sensor is a 3-wire sensor which provides oil pressure information to the ECM. During service, use extreme care in keeping the VLOM assembly free of any contamination or foreign material. Cylinder deactivation may be inhibited for many reasons including the following: * Engine coolant temperature out of range for cylinder activation * Engine vacuum out of range * Brake booster vacuum out of range * Transmission gear incorrect or shift in progress * Accelerator pedal out of range or rate of pedal application to fast * Engine oil pressure and temperature out of range * Engine speed of range * Vehicle speed out of range * Minimum time in V8 mode not met * Maximum V4 mode time exceeded * Decel fuel cutoff active * Reduced engine power active * Torque management active * Catalytic converter over temperature protection active * Piston protection active, knock detected * Cylinder deactivation solenoid driver circuit faults Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Camshaft Position (CMP) Actuator System The camshaft position (CMP) actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation (EGR) control, a wider engine torque range, improved gas mileage, and improved engine idle stability. The CMP actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. For the 6.0 liter (LY6, L76) and the 6.2 liter (L92) engine, the Park position for the CMP actuator and camshaft is 8.5 degrees before top dead center (BTDC) or 17 crankshaft degrees BTDC. The engine control module (ECM) can only command the CMP actuator to retard the valve timing from the Park position or advance the valve timing back to the Park position. The total range of valve timing authority is 31 degrees camshaft rotation, or 62 degrees of crankshaft rotation. The control range is from the Park position of 8.5 degrees camshaft or 17 degrees crankshaft BTDC, to 22.5 degrees camshaft or 45 degrees crankshaft after top dead center (ATDC). CMP Actuator System Operation The camshaft position (CMP) actuator system is controlled by the control module. The control module sends a pulse width modulated 12-volt signal to a CMP actuator solenoid in order to control the amount of engine oil flow to a camshaft actuator passage. There are 2 different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The camshaft actuator is attached to the front of the camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position (CKP). Incorrect engine oil pressure (EOP), viscosity, temperature, engine oil level, or aftermarket engine oil additives can have an adverse affect on camshaft phaser performance. CMP Actuator Solenoid Circuit Diagnostics The engine control module (ECM) monitors the control circuit of the camshaft position (CMP) actuator solenoid for electrical faults. The control module has the ability to determine if a control circuit is open, shorted high, or shorted low. If the control module detects a fault with the CMP actuator solenoid control circuit, DTC P0010 will set. CMP Actuator System Performance Diagnostic The engine control module (ECM) monitors the performance of the camshaft position (CMP) actuator system by monitoring the calibrated desired position and the actual position of the camshaft through the 4X signal of the CMP sensor. If the difference between the actual and desired position is Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Page 4871 greater than a calibrated angle for a calibrated amount of time, DTC P0011 will set. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations Vehicle Speed Sensor: Component Locations Disassembled Views Case and Associated Parts (1 of 2) 1 - Torque Converter Assembly - Size Model Dependent 2 - Pump to Case Bolt 3 - Pump to Case Bolt O-Ring 4 - Oil Pump Assembly 5 - A/T Fluid Pump Seal - Pump to Case 6 - Pump Cover to Case Gasket 7 - Case Bushing 9 - Transmission Vent Assembly 11 - Case Servo Plug 12 - Servo Return Spring 13 - 2nd Apply Piston Pin 14 - Retainer Ring - 2nd Apply Piston 15 - Servo Cushion Spring Retainer 16 - Servo Cushion Spring - Outer 17 - 2nd Apply Piston 18 - Oil Seal Ring - 2nd Apply Piston - Outer 19 - Oil Seal Ring - 2nd Apply Piston - Inner Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 4876 20 - Servo Piston Housing - Inner 21 - O-Ring Seal 22 - Servo Apply Pin Spring 23 - Servo Apply Pin Washer 24 - Retainer Ring - Apply Pin 25 - 4th Apply Piston 26 - Oil Seal Ring - 4th Apply Piston - Outer 27 - O-Ring Seal - 2-4 Servo Cover 28 - 2-4 Servo Cover 29 - Servo Cover Retaining Ring 30 - Case Extension to Case Seal 31 - Case Extension - Model Dependent 32 Case Extension to Case Bolt 33 - Case Extension Bushing 34 - Case Extension Oil Seal Assembly - Model Dependent 34 - Case Extension Oil Seal Assembly - Model Dependent 35 - Speed Sensor Retaining Bolt 36 - Vehicle Speed Sensor (VSS) 37 - O-Ring Seal - VSS to Case Extension 71 Filter Seal 72 - Transmission Oil Filter Assembly - Model Dependent 73 - Transmission Oil Pan Gasket 74 - Chip Collector Magnet 75 - Transmission Oil Pan - Model Dependent 76 Transmission Oil Pan Screw 94 - Converter Housing to Case Bolt 95 - Oil Cooler Quick Connector 96 - Oil Cooler Quick Connect Clip 97 - Converter Housing Access Hole Plug - Model Dependent 98 - Converter Bolt Inspection Plate - Model Dependent 99 - Cup D4 Orifice Plug 102 - Converter Housing - Model Dependent 103 - Main Section Case - Model Dependent 105 - Servo Cushion Spring - Inner - Model Dependent Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 4877 Vehicle Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 4878 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) (M30, TZ0, MYC and MW7or M99 with NQG or NQF) Vehicle Speed Sensor (VSS) (MW7 except NQG or NQF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 4879 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the VSS bolt (2). Tighten the bolt to 11 Nm (97 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4882 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4883 Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4884 Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4885 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the VSS and O-ring seal. Tighten the VSS to 16 Nm (12 lb ft). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4886 Vehicle Speed Sensor: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4887 Vehicle Speed Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the VSS bolt (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4888 Tighten the bolt to 11 Nm (97 lb in). 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4889 Tremec 5-Speed (TZ0) - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4890 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the VSS and O-ring seal. Tighten the VSS to 16 Nm (12 lb ft). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4891 MP 1625/1626-NQF - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4892 MP 3023/3024-NQH - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 4893 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service Precautions Catalytic Converter: Service Precautions Three-Way Catalytic Converter Damage Caution Caution: In order to avoid damaging the replacement three-way catalytic converter, correct the engine misfire or mechanical fault before replacing the three-way catalytic converter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) Catalytic Converter: Service and Repair Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) > Page 4900 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) > Page 4901 Catalytic Converter: Service and Repair Catalytic Converter Replacement (LFA with Exhaust Clamp) Catalytic Converter Replacement (LFA with Exhaust Clamp) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) > Page 4902 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) > Page 4903 Catalytic Converter: Service and Repair Catalytic Converter Replacement Catalytic Converter Replacement (LY6 with Exhaust Flange) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) > Page 4904 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter Replacement (GEN IV Engines With Exhaust Clamp) > Page 4905 Catalytic Converter: Service and Repair Catalytic Converter Replacement - Left Side (Cab Chassis) Catalytic Converter Replacement - Left Side (Cab Chassis) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4915 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4916 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4917 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4918 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4924 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4925 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4926 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4927 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Control Valve: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Canister Purge Control Valve: > 10-03-16-001 > Jul > 10 > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams Canister Purge Solenoid: Diagrams Component Connector End Views Evaporative Emission (EVAP) Canister Purge Solenoid Valve (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Page 4949 Canister Purge Solenoid: Service and Repair Evaporative Emission Canister Purge Solenoid Valve Replacement Removal Procedure Important: Clean all evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting, in order to avoid possible EVAP system contamination. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the EVAP line quick connect fitting from the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service ( See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 3. Disconnect the engine wiring harness electrical connector (2) from the EVAP canister purge solenoid. 4. Disconnect the chassis EVAP line quick connect fitting from the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Page 4950 Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 5. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail. 6. Remove the EVAP canister purge solenoid. Installation Procedure 1. Install the EVAP canister purge solenoid. 2. Install the EVAP canister purge solenoid to the fuel rail and engage the retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Page 4951 3. Connect the engine wiring harness electrical connector (2) to the EVAP canister purge solenoid. 4. Connect the chassis EVAP line quick connect fitting to the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service ( See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 5. Connect the EVAP line quick connect fitting to the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 6. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Volume Control Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4960 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4961 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4962 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4963 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Volume Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4969 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4970 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4971 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Volume Control Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4972 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4981 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4982 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4983 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4984 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4990 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4991 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4992 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Canister Filter: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 4993 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Check Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 5002 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 5003 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 5004 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 5005 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Check Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 5011 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 5012 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 5013 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 02-06-04-037I > Sep > 10 > Emissions - MIL ON/DTC P0446 Stored In ECM > Page 5014 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Diagrams Canister Vent Valve: Diagrams Component Connector End Views Evaporative Emission (EVAP) Canister Vent Solenoid Valve (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > Evaporative Emission Canister Vent Solenoid Valve Replacement (Rear of Tank) Canister Vent Valve: Service and Repair Evaporative Emission Canister Vent Solenoid Valve Replacement (Rear of Tank) Evaporative Emission Canister Vent Solenoid Valve Replacement (Rear of Tank) Removal Procedure Note: Clean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Cut the canister vent solenoid hose (1) approximately 76 mm (3 in) from the evaporative emission canister vent solenoid (2). 3. Disconnect the vent solenoid hose retainers (1). 4. Remove the vent solenoid hose and filter (2). 5. Replace the vent hose with bulk 5/8 in heater hose. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > Evaporative Emission Canister Vent Solenoid Valve Replacement (Rear of Tank) > Page 5021 Installation Procedure 1. Use a hose clamp (1) at the end of the vent hose. 2. Ensure the filter (3) points down. 3. Secure the vent hose with a tie strap (2) to the vent hose tee connector (4). 4. Secure the remaining portion of the vent hose along the frame with tie straps as needed. 5. Position and install the evaporative canister vent solenoid (1) to the vehicle. 6. Secure both ends with hose clamps (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > Evaporative Emission Canister Vent Solenoid Valve Replacement (Rear of Tank) > Page 5022 Canister Vent Valve: Service and Repair Evaporative Emission Canister Vent Solenoid Valve Replacement (Front of Tank) Evaporative Emission Canister Vent Solenoid Valve Replacement (Front of Tank) Removal Procedure Note: Clean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Cut the canister vent solenoid hose (1) approximately 76 mm (3 in) from the evaporative emission canister vent solenoid (2). 3. Pull back on the retaining tab (1) and release the vent solenoid valve (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > Evaporative Emission Canister Vent Solenoid Valve Replacement (Rear of Tank) > Page 5023 4. Disconnect the vent solenoid hose from the plastic retainers (1). 5. Remove the vent solenoid hose. 6. Replace the vent hose with bulk 5/8 in heater hose. Installation Procedure 1. Use a hose clamp (1) at the end of the vent hose. 2. Ensure the filter (3) points down. 3. Secure the vent hose with a tie strap (2) to the vent hose tee connector (4). 4. Use 5/8 in heater hose and secure it along the frame with tie straps as needed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair > Evaporative Emission Canister Vent Solenoid Valve Replacement (Rear of Tank) > Page 5024 5. Position and install the evaporative canister vent solenoid (1) to the vehicle. 6. Use 5/8 in heater hose (2) to secure both ends with hose clamps (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission System Hose/Pipe Evaporative Emissions Hose: Service and Repair Evaporative Emission System Hose/Pipe Evaporative Emission System Hose/Pipe Replacement (15/25 Reg/Ext/Crw Cab With 34 gal Tnk) Removal Procedure Important: Clean all fuel and evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the EVAP pipe from the fuel tank clips (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission System Hose/Pipe > Page 5029 3. Disconnect the EVAP pipe quick connect fittings from the rollover valve and the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Remove the EVAP pipe from the fuel tank clips (1). Installation Procedure 1. Position and connect the EVAP pipe quick connect fittings to the rollover valve and the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 2. Install the EVAP pipe to the fuel tank clips (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission System Hose/Pipe > Page 5030 3. Install the EVAP pipe to the fuel tank clips (1). 4. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission System Hose/Pipe > Page 5031 Evaporative Emissions Hose: Service and Repair Evaporative Emission Line - Engine Evaporative Emission Line Replacement - Engine Removal Procedure Important: Clean all evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the EVAP line quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 3. Disconnect the EVAP line quick connect fitting at the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission System Hose/Pipe > Page 5032 1. Connect the EVAP line quick connect fitting at the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 2. Connect the EVAP line quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 3. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair EGR Cooler: Service and Repair Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement Removal Procedure Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Reposition the EGR cooler pipe clamp and remove the EGR cooler pipe hose (4) from the EGR cooler tube. 3. Remove the upper EGR cooler pipe bolt (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Page 5037 4. Remove the lower EGR cooler pipe bolt (1). 5. Remove the EGR cooler pipe from the engine. Installation Procedure 1. Inspect EGR cooling hose (4) and replace as necessary. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Position the EGR cooler pipe and hose (3) to the engine. Tighten the lower bolt (1) to 9 Nm (80 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Page 5038 3. Install the EGR cooler pipe hose (4) to the EGR cooler tube and reposition the EGR cooler pipe clamp (3). 4. Tighten the clamp bolt (2) to 9 Nm (80 lb in). 5. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair PCV Valve Hose: Service and Repair Positive Crankcase Ventilation Hose/Pipe/Tube Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Remove the positive crankcase ventilation (PCV) hose from the intake manifold fitting and left valve rocker arm cover, if required. 3. Remove the PCV tube (1) from the air cleaner outlet duct, if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 5043 4. Remove the PCV tube (1) from the right valve rocker arm cover fitting (2), if required. 5. Remove the appropriate PCV hose/tube from the vehicle. Installation Procedure 1. Install the appropriate PCV hose/tube to the vehicle. 2. Install the PCV tube (1) to the right valve rocker arm cover fitting (2), if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 5044 Important: Route the PCV tube between the engine harness and generator battery jumper cable. 3. Install the PCV tube (1) to the air cleaner outlet duct, if required. 4. Install the PCV hose to the intake manifold fitting and left valve rocker arm cover, if required. 5. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Service Precautions Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) Fuel Pressure: Testing and Inspection Fuel System Diagnosis (FPCM) Fuel System Diagnosis (FPCM) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for 2 seconds, unless the engine is in Crank or Run. While this voltage is being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure. The fuel system is an electronic returnless on-demand design. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump is contained by the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pump module contains a reverse flow check valve. The check valve maintains fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Reference Information Description and Operation Fuel System Description (See: Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH-48027 Digital Pressure Gauge * J 37287 Fuel Line Shut-off Adapter Circuit/System Verification Note: * Repair all fuel system related DTCs before performing this diagnostic, unless instructed here from a DTC diagnostic. * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. * DO NOT perform the Fuel System Diagnosis if the engine coolant temperature is above 60°C (150°F). High fuel pressure readings may result due to hot soak fuel boiling. With the engine OFF, the fuel pressure may increase beyond the pressure relief valves set point of 690 kPa = / -5 % (100 psi ±5 %). 1. Ignition OFF, all accessories OFF, install a CH-48027 . Refer to Fuel Pressure Gauge Installation and Removal (See: Fuel Pressure Gauge Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) > Page 5051 Installation and Removal). 2. Ignition ON, engine OFF, command the fuel pump ON with a scan tool. Verify the fuel pressure is between 345-690 kPa (50-100 psi) with the pump running. 3. Engine ON with the engine idling at normal operating temperature, the Fuel Rail Pressure Sensor parameter should read between 296.4-310.3 kPa (43-45 psi). Circuit/System Testing Note: * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, engine OFF, command the fuel pump ON with a scan tool and observe the fuel pressure gauge while the fuel pump is operating. Verify the fuel pressure is between 345-690 kPa (50-100 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 2. Verify that the fuel pressure, after the fuel pump is turned off, decreases to 500-599 kPa (72-87 psi), and does not decrease more than 34 kPa (5 psi) in 1 minute from that point. ‹› If the fuel pressure stays above 600 kPa (87 psi), replace the fuel pump module. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair ). 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 . 4. Ignition ON, command the fuel pump ON with a scan tool and bleed the air from the CH-48027 . 5. Command the fuel pump ON and then OFF with a scan tool. 6. Close the valve on the J 37287 . 7. Monitor the fuel pressure for 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module. 4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with the CH-48027 . The fuel pressure should not drop off during acceleration, cruise or hard cornering. ‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections 5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) > Page 5052 Fuel Pressure: Testing and Inspection Fuel Pressure Gauge Installation and Removal Fuel Pressure Gauge Installation and Removal Special Tools CH-48027 Digital Pressure Gauge Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions. Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) > Page 5053 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief (CH-48027) Special Tools CH-48027 - Digital Pressure Gauge Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Page 5057 * The hose connections * The areas surrounding the connections Note: If relieving the fuel pressure for the fuel pressure gauge installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 5061 Idle Speed: Testing and Inspection Throttle/Idle Learn Description The engine control module (ECM) learns the airflow through the throttle body to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to throttle body coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned. An engine that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero. The idle may be unstable or a DTC may set if the learned values do not match the actual airflow. Conditions for Running the Throttle Learn Procedure Reset Procedure * DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set. * Ignition ON, engine OFF. * The vehicle speed sensor (VSS) is 0 km/h (0 mph). Learn Procedure * DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set. * The engine speed is between 450-4,000 RPM. * The manifold absolute pressure (MAP) is greater than 5 kPa. * The mass air flow (MAF) is greater than 2 g/s. * The ignition voltage is greater than 10 volts. Throttle Learn Reset Procedure (Performed after the throttle body is cleaned or replaced) 1. Ignition ON, engine OFF, perform the Idle Learn Reset in Module Setup with a scan tool. 2. Start the engine and monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation value should equal 0 percent and the engine should be idling at a normal idle speed. 3. Clear the DTCs and return to the diagnostic that referred you here. Learn Procedure (Performed after the ECM is flashed or replaced) Note: Do NOT perform this procedure if DTCs are set. Refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle). 1. Start and idle the engine for 3 minutes. 2. With a scan tool, monitor the Desired Idle Speed and the actual Engine Speed. 3. The ECM will start to learn the new idle cells and Desired Idle Speed should start to decrease. 4. Ignition OFF for 60 seconds. 5. Start and idle the engine for 3 minutes. 6. After the 3 minute run time the engine should be idling normal. Note: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. ‹› If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles. 7. After the drive cycle, the engine should be idling normally. ‹› If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6. 8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that referred you here. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5065 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5066 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 2. Remove the accelerator pedal bolts. 3. Remove the accelerator pedal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5067 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Resonator Outlet Duct Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct. 3. Remove the radiator inlet hose clamp retainer from the outlet duct. 4. Loosen the air cleaner outlet duct clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 5. Loosen the air cleaner outlet duct clamp (2) at the throttle body. 6. Lift up the air cleaner outlet duct at the resonator tab in order to separate the resonator from the stud on the intake manifold. 7. Remove the air cleaner outlet duct from the throttle body and MAF/IAT sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 5072 Installation Procedure 1. Install the air cleaner outlet duct to the throttle body and MAF/IAT sensor. Ensure that the resonator tab aligns with the stud on the intake manifold. 2. Push down on the air cleaner outlet duct resonator directly over the resonator tab in order to secure the resonator to the stud on the intake manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 3. Tighten the air cleaner outlet duct clamp (2) at the throttle body to 4 Nm(35 lb in). 4. Tighten the air cleaner outlet duct clamp (1) to 4 Nm(35 lb in) at the MAF/IAT sensor. 5. Install the radiator inlet hose clamp retainer to the outlet duct. 6. Install the PCV line (1) to the air cleaner outlet duct. 7. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5079 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5080 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5081 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5082 Installation Procedure Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the MAF/IAT sensor adapter clamp. Tighten the clamp to 4 Nm (35 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. Fuel: Technical Service Bulletins Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. INFORMATION Bulletin No.: 10-06-04-015 Date: December 08, 2010 Subject: General Motors' Position Regarding Use of E15 in Model Year 2007 and Newer Vehicles Models: 2007-2011 GM Passenger Cars and Trucks General Motors' position regarding the Environmental Protection Agency announcement allowing the use of E 15 in 2007 and newer vehicles: - General Motors' remains focused on securing a safe and positive driving experience for our customers. GM believes that the waiver decision by the EPA regarding E 15 could lead to confusion for consumers as to what fuel their vehicle should use. In response, we will continue to encourage our customers to refer to their vehicle Owner Manual for proper fuel designation. The vehicle Owner Manual specifies that fuels containing more than 10 percent ethanol should not be used in GM vehicles that do not have a flex fuel designation. - GM has the largest fleet of flex fuel vehicles on the road today (over 4 million in the U.S.) and these vehicles can safely use ethanol blends of up to 85 percent ethanol. So blends of E 15 (15 percent ethanol), as in the partial waiver announced, are appropriate for these vehicles. However, ethanol blends greater than E 10 should not be used in GM vehicles that do not have a flex fuel designation as they are not designed and certified to run on gasoline consisting of more than 10 percent ethanol-blend volume to avoid any unintended consequences, as per: their Owner Manual. - We believe biofuels, especially E 85 ethanol, are an effective near-term solution to reduce petroleum dependence and the carbon footprint of driving. As the global leader in producing vehicles designed to handle ethanol blends from E 0 to E 85, GM offers 19 flexible-fuel vehicles for the 2011 model year. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 5087 Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 5088 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 5089 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 5090 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 5091 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 5092 Fuel: Service Precautions Gasoline/Gasoline Vapors Warning Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Alcohol/Contaminants-in-Fuel Diagnosis (Without Special Tool) Fuel: Testing and Inspection Alcohol/Contaminants-in-Fuel Diagnosis (Without Special Tool) Alcohol/Contaminants-in-Fuel Diagnosis (Without Special Tool) Description Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust, or deterioration. Alcohol concentrations of 10 percent or greater in fuel can be detrimental to fuel system components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations of no more than 10 percent. Some fuels, such as E85, contain a very high percentage of ethanol. Fuel with more than 10 percent ethanol may cause driveability conditions such as hesitation, lack of power, stalling, or no start. Alcohol in Fuel Testing Procedure Important: Do not perform this diagnostic procedure unless directed to do so by another diagnostic. The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If alcohol contamination is suspected then use the following procedure to test the fuel quality. 1. Using a 100 ml (3.4 oz) specified cylinder with 1 ml (0.03 oz) graduation marks, fill the cylinder with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid volume to 100 ml (3.4 oz) and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml (0.34 oz). For example, if the volume of the lower layer is increased to 15 ml (0.51 oz), this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. Particulate Contaminants in Fuel Testing Procedure The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, use the following procedure to diagnose the fuel. 1. Using an approved fuel container, draw approximately 0.5 liter (0.13 gal) of fuel. 2. Place the cylinder on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by a white or light brown crystals. Rubber will appear as black and irregular particles. If particles are found clean the entire fuel system thoroughly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Alcohol/Contaminants-in-Fuel Diagnosis (Without Special Tool) > Page 5095 Fuel: Testing and Inspection Fuel Composition Diagnosis Fuel Composition Diagnosis System Description When an E85 compatible vehicle is built, an engine control module (ECM) or powertrain control module (PCM) replaced, or when the learned alcohol content has been reset with a scan tool, the fuel system will need to contain ASTM gasoline with 10 percent or less ethanol content. If the fuel in the fuel system needs to be drained and replaced with ASTM gasoline, the engine will need to run at operating temperature and consume at least 1 liter (0.3 gallon) of fuel before the system will recognize the correct alcohol content. Either ASTM gasoline or ASTM E85 fuel can then be used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Alcohol/Contaminants-in-Fuel Diagnosis (Without Special Tool) > Page 5096 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Alcohol/Contaminants-in-Fuel Diagnosis (Without Special Tool) > Page 5097 Fuel: Testing and Inspection Alcohol/Contaminants-in-Fuel Diagnosis (Special Tool) Alcohol/Contaminants-in-Fuel Diagnosis (Special Tool) Description Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Ethanol concentrations of greater than 10 percent can cause driveability conditions and fuel system deterioration. Fuel with more than 10 percent ethanol could result in driveability conditions such as hesitation, lack of power, stalling , or no start. Excessive concentrations of ethanol used in vehicles not designed for it may cause fuel system corrosion, deterioration of rubber components, and fuel filter restriction. Test Procedure Important: Do not perform this diagnostic procedure unless directed to do so by another diagnostic. 1. Test the fuel composition using J 44175 Fuel Composition Tester and J44175-3 Instruction Manual. 2. Subtract 50 from the reading on the DMM in order to obtain the percentage of alcohol in the fuel sample. Refer to the examples in the Fuel Composition Test Examples table. 3. If the fuel sample contains more than 15 percent ethanol, add fresh, regular gasoline to the vehicle's fuel tank. 4. Test the fuel composition. 5. If testing shows the ethanol percentage is still more than 15 percent, replace the fuel in the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief (CH-48027) Special Tools CH-48027 - Digital Pressure Gauge Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 5102 * The hose connections * The areas surrounding the connections Note: If relieving the fuel pressure for the fuel pressure gauge installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Fuel Injector Resistance ...................................................................................................................... ................................................................ 11-14 ohms Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 5107 Fuel Injector: Pressure, Vacuum and Temperature Specifications Pressure Drop No more than ....................................................................................................................................... .......................................... 34 kPa (5 psi) in 1 minute Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 5108 Fuel Injector: Diagrams Component Connector End Views Fuel Injector 1 (Gas except LU3) Fuel Injector 1 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 5109 Fuel Injector 2 (Gas except LU3) Fuel Injector 2 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 5110 Fuel Injector 3 (Gas except LU3) Fuel Injector 3 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 5111 Fuel Injector 4 (Gas except LU3) Fuel Injector 4 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 5112 Fuel Injector 5 (Gas except LU3) Fuel Injector 5 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 5113 Fuel Injector 6 (Gas except LU3) Fuel Injector 6 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 5114 Fuel Injector 7 (Gas except LU3) Fuel Injector 8 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 5115 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Diagnosis (CH 47976) Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (CH 47976) Fuel Injector Diagnosis (CH47976) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provide an overview of each diagnostic category. Circuit/System Description The control module enables the appropriate fuel injector pulse for each cylinder. The ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. The CH-47976 , is used to test the fuel pump, fuel system leak down, and the fuel injectors. Following the User Guide, CH 47976-11, and the on screen prompts or selections, will indicate the steps required to perform each of the available tests. The tester will perform all of the tests automatically and display results of the test. The results can also be down loaded for storage and printing. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Special Tools CH-47976 Active Fuel Injector Tester Component Testing Fuel Injector Coil Test Verify the resistance of each fuel injector with one of the following methods: * If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of each fuel injector should be 11-14 ohms. ‹› If the injectors measure OK, perform the Active Fuel Injector Tester (AFIT) Test Procedure. ‹› If not within the specified range, replace the fuel injector. * If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value. The difference between the lowest value and the highest value should be equal to or less than 3 ohms. ‹› If the difference is equal to or less than 3 ohms, refer to AFIT Test Procedure. ‹› If the difference is more than 3 ohms, add all of the fuel injector resistance values to obtain a total resistance value. Divide the total resistance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Diagnosis (CH 47976) > Page 5118 value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest individual fuel injector resistance value from the average resistance value. Compute the difference between the highest individual fuel injector resistance value and the average resistance value. Replace the fuel injector that displays the greatest difference above or below the average. Important: * DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F). Irregular fuel pressure readings may result due to hot soak fuel boiling. * Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. AFIT Test Procedure 1. Turn OFF all accessories. 2. Turn OFF the ignition. 3. Install the AFIT. Refer to the AFIT User Guide. 4. Turn ON the AFIT and select the vehicle. 5. Turn ON the ignition and perform the Injector Test. ‹› If the AFIT aborts testing due to fuel pressure or fuel leak down, refer to Fuel System Diagnosis (Without FPCM) (See: Fuel Pump/Testing and Inspection)Fuel System Diagnosis (FPCM) (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics). 6. View the test results. ‹› If any injector exceeds the recommended tolerance, replace the injector(s), E-85 only. All other engine, refer to Fuel Injector Cleaning (See: Service and Repair/Procedures). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Fuel Injector Replacement (See: Service and Repair/Removal and Replacement) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Diagnosis (CH 47976) > Page 5119 Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (J39021 or Scan Tool) Fuel Injector Diagnosis (J39021 or Scan Tool) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provide an overview of each diagnostic category. Circuit/System Description The control module enables the appropriate fuel injector pulse for each cylinder. The ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. When performing the fuel injector balance test, the scan tool is first used to energize the fuel pump relay. The fuel injector tester or the scan tool is then used to pulse each injector for a precise amount of time, allowing a measured amount of the fuel to be injected. This causes a drop in the system fuel pressure that can be recorded and used to compare each injector. Diagnostic Aids * Monitoring the misfire current counters, or misfire graph, may help to isolate the fuel injector that is causing the condition. * Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. * Perform the fuel injector coil test within the conditions of the customer's concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) DTC Type Reference Powertrain Diagnostic Trouble Code (DTC) Type Definitions (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Powertrain Diagnostic Trouble Code (DTC) Type Definitions) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH-48027 Digital Pressure Gauge * J 39021 Fuel Injector Coil and Balance Tester * J 44602 Injector Test Adapter Component Testing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Diagnosis (CH 47976) > Page 5120 Fuel Injector Coil Test Verify the resistance of each fuel injector with one of the following methods: * If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of each fuel injector should be 11-14 ohms. ‹› If the injectors measure OK, perform the Fuel Injector Balance Test - Fuel Pressure Test. ‹› If not within the specified range, replace the fuel injector. * If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value. The difference between the lowest value and the highest value should be equal to or less than 3 ohms. ‹› If the difference is equal to or less than 3 ohms, refer to Fuel Injector Balance Test - Fuel Pressure Test for further diagnosis of the fuel injectors. ‹› If the difference is more than 3 ohms, add all of the fuel injector resistance values to obtain a total resistance value. Divide the total resistance value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest individual fuel injector resistance value from the average resistance value. Compute the difference between the highest individual fuel injector resistance value and the average resistance value. Replace the fuel injector that displays the greatest difference above or below the average. Important: * DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F). Irregular fuel pressure readings may result due to hot soak fuel boiling. * Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. Fuel Injector Balance Test-Fuel Pressure Test 1. Install a CH-48027 . Refer to Fuel Pressure Gauge Installation and Removal (See: Fuel Pressure/Testing and Inspection/Fuel Pressure Gauge Installation and Removal). 2. Turn ON the ignition, with the engine OFF. Important: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 3. Command the fuel pump relay ON with a scan tool. 4. Observe the fuel pressure gauge with the fuel pump commanded ON. The fuel pressure should be 345-414 kPa (50-60 psi). ‹› If the fuel pressure is not 345-414 kPa (50-60 psi), refer to Fuel System Diagnosis (Without FPCM) (See: Fuel Pump/Testing and Inspection )Fuel System Diagnosis (FPCM) (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics). 5. Monitor the CH-48027 for one minute. The fuel pressure should not decrease more than 34 kPa (5 psi). ‹› If the fuel pressure decreases more than 34 kPa (5 psi), refer to Fuel System Diagnosis (Without FPCM) (See: Fuel Pump/Testing and Inspection)Fuel System Diagnosis (FPCM) (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics). 6. Perform the Fuel Injector Balance Test with Special Tool or the Fuel Injector Balance Test with Scan Tool. Fuel Injector Balance Test with Special Tool 1. Install a CH-48027 . Refer to Fuel Pressure Gauge Installation and Removal (See: Fuel Pressure/Testing and Inspection/Fuel Pressure Gauge Installation and Removal). 2. Set the amperage supply selector switch on the fuel injector tester to the Balance Test 0.5-2.5 amp position. 3. Connect the J 39021 to a fuel injector with a J 44602 . 4. Command the fuel pump relay ON and then OFF three times with a scan tool. On the last command, as the fuel pressure begins to slowly degrade and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record this fuel pressure. This is the starting pressure at which you will pulse each injector. 5. Command the fuel pump relay ON one more time and energize the fuel injector by depressing the Push to Start Test button on the J 39021 at the previously selected pressure. 6. After the injector stops pulsing, select Min from the Display Mode on the CH-48027 and record the Min pressure. Important: New test results will not be recorded if the Min/Max results are not cleared after each injector is tested. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Diagnosis (CH 47976) > Page 5121 7. Clear the Min/Max results on the CH-48027 . 8. Select Normal from the Display Mode on the CH-48027 . 9. Repeat steps 2 and 4 through 7 for each fuel injector. 10. Perform the Pressure Drop Calculation. Fuel Injector Balance Test with Scan Tool 1. Command the fuel pump relay ON and then OFF three times with a scan tool. On the last command, as the fuel pressure begins to slowly degrade and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record this fuel pressure. This is the starting pressure at which you will pulse each injector. 2. With a scan tool, select the Fuel Injector Balance Test function within the Special Functions menu. 3. Select an injector to be tested. 4. Press Enter to prime the fuel system. 5. Energize the fuel injector by depressing the Pulse Injector button on the scan tool at the previously selected pressure. 6. After the injector stops pulsing, select Min from the Display Mode on the CH-48027 and record the Min pressure. Important: New test results will not be recorded if the Min/Max results are not cleared after each injector is tested. 7. Clear the Min/Max results on the CH-48027 . 8. Select Normal from the Display Mode on the CH-48027 . 9. Press Enter on the scan tool to bring you back to the Select Injector screen. 10. Repeat steps 3 through 9 for each fuel injector. 11. Perform the Pressure Drop Calculation. Pressure Drop Calculation 1. Subtract the minimum pressure from the starting pressure for one fuel injector. The result is the pressure drop value. 2. Obtain a pressure drop value for each fuel injector. 3. Add all of the individual pressure drop values except for the injector suspected of being faulty. This is the total pressure drop. 4. Divide the total pressure drop by the number of fuel injectors that were added together. This is the average pressure drop. The difference between any individual pressure drop and the average pressure drop should not be more than 20 kPa (3 psi). ‹› If the difference between any individual pressure drop and the average pressure drop is more than 20 kPa (3 psi), replace the fuel injector, E-85 only. All other engine, refer to Fuel Injector Cleaning (See: Service and Repair/Procedures). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Fuel Injector Replacement (See: Service and Repair/Removal and Replacement) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures Fuel Injector: Procedures Fuel Injector Cleaning Special Tools * J 37287 Fuel Line Shut-Off Adapters * J 35800-A Fuel Injector Cleaner * J 42873-1 3/8 Fuel Line Shut-Off Valve * J 42873-2 5/16 Return Pipe Shut-Off Valve * J 42964-1 3/8 Fuel Pipe Shut-Off Valve * J 42964-2 5/16 Fuel Pipe Shut-Off Valve Caution: * GM Upper Engine and Fuel Injector Cleaner is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. * Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank, as it may damage the fuel pump and other system components. * Do not exceed the recommended cleaning solution concentration. Higher concentrations may damage fuel system components. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure. Note: Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have the injectors replaced. 1. Obtain J 35800-A (2). Note: Make sure the valve at the bottom of the canister (3) is closed. 2. For 4, 5, and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner twin reservoir container into the J 35800-A , injector cleaning tank, then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. 3. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner twin reservoir container into the J 35800-A , injector cleaning tank, then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for an 8 cylinder engine. The 8 cylinder engines receive 960 ml total fluid-120 ml (4 oz) of GM Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline. 4. Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional instructions provided with the tool. 5. Electrically disable the vehicle fuel pump by removing the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. 6. Disconnect the fuel feed and return line, if equipped, at the fuel rail. Plug the fuel feed and return line, if equipped, coming off the fuel rail with J 37287 , or J 42964-1 , and J 42964-2 or J 42873-1 , and J 42873-2 as appropriate for the fuel system. 7. Connect the J 35800-A to the vehicle fuel rail. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5124 8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls due to lack of fuel. This should take approximately 15-20 minutes. 10. Turn the ignition to the OFF position. 11. Injectors should be flow-tested at this point. If further cleaning is needed, a repeat of the above procedure should be done. When the injector restriction returns to zero, proceed to step 12. 12. Disconnect the J 35800-A from the fuel rail. 13. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 14. Remove the J 37287 , or J 42964-1 and J 42964-2 , or J 42873-1 and J 42873-2 and reconnect the vehicle fuel feed and return lines. 15. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 16. Pour the entire contents of GM Fuel System Treatment Plus, GM P/N 88861011 (Canadian P/N 88861012) into a nearly empty tank and advise the customer to refuel with up to 76 L (20 gal) of fuel. 17. Advise the customer to use only a Top Tier Detergent gasoline and to add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure. 18. Road test the vehicle to verify that the customer concern has been corrected. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5125 Fuel Injector: Removal and Replacement Fuel Injector Replacement Removal Procedure Caution: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method. Note: * An 8-digit identification number is located on the fuel rail. Refer to this identification number when servicing or when part replacement is required. * The engine oil may be contaminated with fuel if the fuel injectors are leaking. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 3. Remove the engine wiring harness bracket nut (1). 4. Disconnect the engine wiring harness electrical connector (2) from the evaporative emission (EVAP) purge solenoid. 5. Disconnect the engine wiring harness electrical connector (3) from the generator. 6. Disconnect the engine wiring harness electrical connector (4) from the manifold absolute pressure (MAP) sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5126 7. Remove the connector position assurance (CPA) retainer (2). 8. Disconnect the engine wiring harness electrical connector (1) from the ignition coil main electrical connector. 9. Disconnect the engine wiring harness electrical connectors (3) from the fuel injectors, perform the following: 1. Mark the connectors to their corresponding injectors to ensure correct reassembly. 2. Pull the CPA retainer on the connector up 1 click. 3. Push the tab on the connector in. 4. Disconnect the fuel injector electrical connector. 10. Remove the CPA retainer (2). 11. Disconnect the engine wiring harness electrical connector (1) from the ignition coil main electrical connector. 12. Disconnect the engine wiring harness electrical connector (3) from the electronic throttle control. 13. Disconnect the engine wiring harness electrical connectors (7) from the fuel injectors, perform the following: 1. Mark the connectors to their corresponding injectors to ensure correct reassembly. 2. Pull the CPA retainer on the connector up 1 click. 3. Push the tab on the connector in. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5127 4. Disconnect the fuel injector electrical connector. 14. Remove the engine wiring harness clip (4) from the generator battery jumper cable. 15. Remove the engine wiring harness clip (6) from the ignition coil bracket stud. 16. Remove the negative battery cable stud (1) from the right cylinder head. 17. Remove the negative battery cable terminal (2) and engine wiring harness ground terminal (3) from the cylinder head. 18. Remove the engine wiring harness clip bolt (3) from the generator bracket. 19. Gather the branches of the engine wiring harness and reposition the aside. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5128 20. Remove the positive crankcase ventilation (PCV) hose. 21. Disconnect the chassis fuel feed pipe (2) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5129 22. Disconnect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 23. Disconnect the chassis EVAP tube quick connect fitting at the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 24. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail. 25. Remove the EVAP tube and purge solenoid. 26. Remove the fuel rail bolts. Caution: * Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components. * Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages. Note: Before removal, clean the fuel rail with a spray type engine cleaner, such as GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5130 Note: Lift evenly on both sides of the fuel rail until all injectors are removed from their bores. 27. Remove the fuel rail assembly. 28. Remove the fuel injector retainers (1). 29. Remove the fuel injectors (3) from the fuel rail. 30. Remove and discard the fuel injector upper and lower O-ring seals (2 and 4). Installation Procedure 1. Lubricate the NEW fuel injector O-ring seals with clean engine oil. 2. Install the NEW fuel injector upper and lower O-ring seals (2 and 4) onto the injectors. 3. Install the fuel injectors (3) into the fuel rails. 4. Install the fuel injector retainers (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5131 5. Ensure the fuel injector lower O-ring seals are adequately lubricated, if not lubricate the fuel injector lower O-ring seals with clean engine oil. 6. Position the fuel rail onto the intake manifold. 7. Firmly push down on both the centers of the left and right fuel rails, until the rails are fully seated against the intake manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Push down firmly on both sides of the rail until all injectors have been seated into their bores. 8. Install the fuel rail bolts. Tighten the bolts to 10 Nm (89 lb in). 9. Install the EVAP tube and purge solenoid. 10. Install the EVAP canister purge solenoid to the fuel rail bracket and engage the retainer. 11. Connect the chassis EVAP tube quick connect fitting at the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 12. Connect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5132 Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 13. Connect the chassis fuel feed pipe (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 14. Install the PCV hose. 15. Gather the branches of the engine wiring harness and position over the top of the engine. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5133 16. Position the engine wiring harness clip to the generator bracket and install the clip bolt (3). Tighten the bolts to 9 Nm (80 lb in). 17. Position the negative battery cable terminal (2) and engine wiring harness ground terminal (3) to the right cylinder head. 18. Install the negative battery cable stud (1) to the cylinder head. Tighten the stud to 25 Nm (18 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5134 19. Connect the engine wiring harness electrical connector (1) to the ignition coil main electrical connector. 20. Install the CPA retainer (2). 21. Connect the engine wiring harness electrical connector (3) to the electronic throttle control. 22. Connect the engine wiring harness electrical connectors (7) to the fuel injectors, perform the following: 1. Ensure that the CPA retainer is pulled out 1 click. 2. Connect the electrical connectors to their corresponding injectors. 3. Push the CPA retainer in 1 click. 4. Ensure that the connector is secured. 23. Install the engine wiring harness clip (4) to the generator battery jumper cable. 24. Install the engine wiring harness clip (6) to the ignition coil bracket stud. 25. Connect the engine wiring harness electrical connector (1) to the ignition coil main electrical connector. 26. Install the CPA retainer (2). 27. Connect the engine wiring harness electrical connectors (3) to the fuel injectors, perform the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5135 1. Ensure that the CPA retainer is pulled out 1 click. 2. Connect the electrical connectors to their corresponding injectors. 3. Push the CPA retainer in 1 click. 4. Ensure that the connector is secured. 28. Connect the engine wiring harness electrical connector (4) to the MAP sensor. 29. Connect the engine wiring harness electrical connector (3) to the generator. 30. Connect the engine wiring harness electrical connector (2) to the EVAP purge solenoid. 31. Install the engine wiring harness bracket nut (1). Tighten the nut to 5 Nm (44 lb in). 32. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 33. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for leaks. 34. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service Fuel Line Coupler: Service and Repair Metal Collar Quick Connect Fitting Service Metal Collar Quick Connect Fitting Service Special Tools J 41769 Fuel Line Quick Disconnect Tool Disconnect Procedure 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Remove the fuel line retainer. Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 3. Using compressed air, blow any dirt or debris from around the connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 5140 4. Using the correct tool from the J 41769 , insert the tool into the female connector end, then push inward in order to release the quick connect locking tabs. 5. Pull the fuel line connection apart. Caution: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 6. Use a clean shop towel in order to wipe off the male connection end. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. Connect Procedure Warning In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male connection end. 2. Push both sides of the fitting together in order to engage the retaining tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 5141 3. Once installed, pull on both sides of the connection in order to ensure the connection is secure. 4. Install the fuel line retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 5142 Fuel Line Coupler: Service and Repair Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service Disconnect Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Note: There are several types of Plastic Collar Fuel and Evaporative Emission Quick Connect Fittings used on this vehicle. * Bartholomew (1) * Q Release (2) * Squeeze to Release (3) * Sliding Retainer (4) * Push Down TI (5) The following instructions apply to all of these types of Plastic Collar Quick Connect Fittings except where indicated. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair). Warning: Refer to Safety Glasses Warning (See: Service Precautions/Technician Safety Information/Safety Glasses Warning). Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (See: Emission Control Systems/Evaporative Emissions System/Service Precautions/Vehicle Damage Warnings). 2. Using compressed air, blow any dirt or debris from around the connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 5143 3. This step applies to Bartholomew style connector ONLY. Squeeze the plastic quick connect fitting release tabs. 4. This step applies to Release Tab style connector ONLY. Release the fitting by pushing the tab toward the other side of the slot in the fitting. 5. This step applies to the Squeeze to Release style connector ONLY. Squeeze where indicated by the arrows shown above on both sides of the plastic ring surrounding the quick connect fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 5144 6. This step applies to the Sliding Retainer style connector ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move try pressing the tab in from the opposite side. The tab will only move in one direction. 7. This step applies to the Push Down TI style connector ONLY. Release the fitting by pressing on the tab indicated by the arrow. Quick Connect Fittings Warning: Refer to Relieving Fuel Pressure Warning (See: Fuel Pressure/Service Precautions). 8. Pull the connection apart. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 5145 Connect Procedure Warning: Refer to Fuel Pipe Fitting Warning (See: Service Precautions/Fuel Pipe Fitting Warning) 1. Apply a few drops of clean engine oil to the male connection end. 2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place. 3. Once installed, pull on both sides of the connection in order to make sure the connection is secure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module (Gas except JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams > Page 5149 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams Fuel Pressure Sensor/Switch: Diagrams Component Connector End Views Fuel Pressure Sensor (Gas except LU3 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5153 Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the chassis wiring harness electrical connector (1) from the fuel pressure sensor. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. 4. Remove the fuel pressure sensor from the fuel line. 5. Remove and discard the fuel pressure sensor O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5154 1. Lubricate a NEW fuel pressure sensor O-ring seal with clean engine oil. 2. Install the NEW fuel pressure sensor O-ring seal onto the fuel line fitting. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the fuel pressure sensor to the fuel line. Tighten the sensor to 15 Nm (11 lb ft). 5. Connect the chassis wiring harness electrical connector (1) to the fuel pressure sensor. 6. Lower the vehicle. 7. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5155 4. Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Service Precautions Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) Fuel Pressure: Testing and Inspection Fuel System Diagnosis (FPCM) Fuel System Diagnosis (FPCM) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for 2 seconds, unless the engine is in Crank or Run. While this voltage is being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure. The fuel system is an electronic returnless on-demand design. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump is contained by the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pump module contains a reverse flow check valve. The check valve maintains fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Reference Information Description and Operation Fuel System Description (See: Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH-48027 Digital Pressure Gauge * J 37287 Fuel Line Shut-off Adapter Circuit/System Verification Note: * Repair all fuel system related DTCs before performing this diagnostic, unless instructed here from a DTC diagnostic. * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. * DO NOT perform the Fuel System Diagnosis if the engine coolant temperature is above 60°C (150°F). High fuel pressure readings may result due to hot soak fuel boiling. With the engine OFF, the fuel pressure may increase beyond the pressure relief valves set point of 690 kPa = / -5 % (100 psi ±5 %). 1. Ignition OFF, all accessories OFF, install a CH-48027 . Refer to Fuel Pressure Gauge Installation and Removal (See: Fuel Pressure Gauge Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) > Page 5162 Installation and Removal). 2. Ignition ON, engine OFF, command the fuel pump ON with a scan tool. Verify the fuel pressure is between 345-690 kPa (50-100 psi) with the pump running. 3. Engine ON with the engine idling at normal operating temperature, the Fuel Rail Pressure Sensor parameter should read between 296.4-310.3 kPa (43-45 psi). Circuit/System Testing Note: * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, engine OFF, command the fuel pump ON with a scan tool and observe the fuel pressure gauge while the fuel pump is operating. Verify the fuel pressure is between 345-690 kPa (50-100 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 2. Verify that the fuel pressure, after the fuel pump is turned off, decreases to 500-599 kPa (72-87 psi), and does not decrease more than 34 kPa (5 psi) in 1 minute from that point. ‹› If the fuel pressure stays above 600 kPa (87 psi), replace the fuel pump module. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair ). 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 . 4. Ignition ON, command the fuel pump ON with a scan tool and bleed the air from the CH-48027 . 5. Command the fuel pump ON and then OFF with a scan tool. 6. Close the valve on the J 37287 . 7. Monitor the fuel pressure for 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module. 4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with the CH-48027 . The fuel pressure should not drop off during acceleration, cruise or hard cornering. ‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections 5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) > Page 5163 Fuel Pressure: Testing and Inspection Fuel Pressure Gauge Installation and Removal Fuel Pressure Gauge Installation and Removal Special Tools CH-48027 Digital Pressure Gauge Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions. Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis (FPCM) > Page 5164 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood Fuel Pump Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5169 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5170 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5171 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5172 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5173 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5174 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5175 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5176 Fuel Pump Relay: Locations Harness Routing Views Harness Routing Views Chassis Harness - Front Engine Compartment (31 Series) 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 5177 Fuel Pump Relay: Diagrams Component Connector End Views Fuel Pump Relay - Secondary (LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair Fuel Rail: Service and Repair Fuel Injection Fuel Rail Assembly Replacement Removal Procedure Note: An 8-digit identification number is located on the fuel rail. Refer to this identification number when servicing or when part replacement is required. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 3. Remove the engine wiring harness bracket nut (1). 4. Disconnect the engine wiring harness electrical connector (2) from the evaporative emission (EVAP) purge solenoid. 5. Disconnect the engine wiring harness electrical connector (3) from the generator. 6. Disconnect the engine wiring harness electrical connector (4) from the manifold absolute pressure (MAP) sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 5181 7. Remove the connector position assurance (CPA) retainer (2). 8. Disconnect the engine wiring harness electrical connector (1) from the ignition coil main electrical connector. 9. Disconnect the engine wiring harness electrical connectors (3) from the fuel injectors, perform the following: 1. Mark the connectors to their corresponding injectors to ensure correct reassembly. 2. Pull the CPA retainer on the connector up 1 click. 3. Push the tab on the connector in. 4. Disconnect the fuel injector electrical connector. 10. Remove the CPA retainer (2). 11. Disconnect the engine wiring harness electrical connector (1) from the ignition coil main electrical connector. 12. Disconnect the engine wiring harness electrical connector (3) from the electronic throttle control. 13. Disconnect the engine wiring harness electrical connectors (7) from the fuel injectors, perform the following: 1. Mark the connectors to their corresponding injectors to ensure correct reassembly. 2. Pull the CPA retainer on the connector up 1 click. 3. Push the tab on the connector in. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 5182 4. Disconnect the fuel injector electrical connector. 14. Remove the engine wiring harness clip (4) from the generator battery jumper cable. 15. Remove the engine wiring harness clip (6) from the ignition coil bracket stud. 16. Remove the negative battery cable stud (1) from the right cylinder head. 17. Remove the negative battery cable terminal (2) and engine wiring harness ground terminal (3) from the cylinder head. 18. Remove the engine wiring harness clip bolt (3) from the generator bracket. 19. Gather the branches of the engine wiring harness and reposition the aside. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 5183 20. Remove the positive crankcase ventilation (PCV) hose. 21. Disconnect the chassis fuel feed pipe (2) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 5184 22. Disconnect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 23. Disconnect the chassis EVAP tube quick connect fitting at the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 24. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail. 25. Remove the EVAP tube and purge solenoid. 26. Remove the fuel rail bolts. Caution: * Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components. * Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages. Note: * Before removal, clean the fuel rail with a spray type engine cleaner, such as GM X-30A or equivalent, if necessary. Follow the package Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 5185 instructions. Do not soak the fuel rail in liquid cleaning solvent. * Lift evenly on both sides of the fuel rail until all injectors are removed from their bores. 27. Remove the fuel rail assembly. 28. Remove the fuel injector retainers (1). 29. Remove the fuel injectors (3) from the fuel rail. 30. Remove and discard the fuel injector upper and lower O-ring seals (2 and 4). Installation Procedure 1. Lubricate the NEW fuel injector O-ring seals with clean engine oil. 2. Install the NEW fuel injector upper and lower O-ring seals (2 and 4) onto the injectors. 3. Install the fuel injectors (3) into the fuel rails. 4. Install the fuel injector retainers (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 5186 5. Ensure the fuel injector lower O-ring seals are adequately lubricated, if not lubricate the fuel injector lower O-ring seals with clean engine oil. 6. Position the fuel rail onto the intake manifold. 7. Firmly push down on both the centers of the left and right fuel rails, until the rails are fully seated against the intake manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Push down firmly on both sides of the rail until all injectors have been seated into their bores. 8. Install the fuel rail bolts. Tighten the bolts to 10 Nm (89 lb in). 9. Install the EVAP tube and purge solenoid. 10. Install the EVAP canister purge solenoid to the fuel rail bracket and engage the retainer. 11. Connect the chassis EVAP tube quick connect fitting at the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 12. Connect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 5187 Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 13. Connect the chassis fuel feed pipe (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 14. Install the PCV hose. 15. Gather the branches of the engine wiring harness and position over the top of the engine. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 5188 16. Position the engine wiring harness clip to the generator bracket and install the clip bolt (3). Tighten the bolt to 9 Nm (80 lb in). 17. Position the negative battery cable terminal (2) and engine wiring harness ground terminal (3) to the right cylinder head. 18. Install the negative battery cable stud (1) to the cylinder head. Tighten the stud to 25 Nm (18 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 5189 19. Connect the engine wiring harness electrical connector (1) to the ignition coil main electrical connector. 20. Install the CPA retainer (2). 21. Connect the engine wiring harness electrical connector (3) to the electronic throttle control. 22. Connect the engine wiring harness electrical connectors (7) to the fuel injectors, perform the following: 1. Ensure that the CPA retainer is pulled out 1 click. 2. Connect the electrical connectors to their corresponding injectors. 3. Push the CPA retainer in 1 click. 4. Ensure that the connector is secured. 23. Install the engine wiring harness clip (4) to the generator battery jumper cable. 24. Install the engine wiring harness clip (6) to the ignition coil bracket stud. 25. Connect the engine wiring harness electrical connector (1) to the ignition coil main electrical connector. 26. Install the CPA retainer (2). 27. Connect the engine wiring harness electrical connectors (3) to the fuel injectors, perform the following: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 5190 1. Ensure that the CPA retainer is pulled out 1 click. 2. Connect the electrical connectors to their corresponding injectors. 3. Push the CPA retainer in 1 click. 4. Ensure that the connector is secured. 28. Connect the engine wiring harness electrical connector (4) to the MAP sensor. 29. Connect the engine wiring harness electrical connector (3) to the generator. 30. Connect the engine wiring harness electrical connector (2) to the EVAP purge solenoid. 31. Install the engine wiring harness bracket nut (1). Tighten the nut to 5 Nm (44 lb in). 32. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 33. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for leaks. 34. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle half way. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the fuel tank fill pipe ground wire bolt (3). 6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5196 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1). 8. Open the axle vent hose clip on the fuel fill pipe bracket. 9. Remove the rear axle vent hose from the clip. 10. Disconnect the fuel fill pipe recirculation line quick connect fitting (2) from the evaporative emission (EVAP) rear hose. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 11. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 12. Remove the fuel tank fill pipe. 13. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5197 1. Remove the cap from the opening on the fuel tank. 2. Position the fuel tank fill pipe. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten the clamp to 2.5 Nm (22 lb in). 4. Connect the fuel fill pipe recirculation line quick connect fitting (2) to the EVAP rear hose. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. 6. Close the axle vent hose clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5198 7. Position the chassis harness ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket. 8. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole. 9. Install the fuel tank fill pipe ground wire bolt (3). Tighten the bolt to 9 Nm (80 lb in). 10. Lower the vehicle. 11. Install the fuel tank filler housing. 12. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the screws to 2.3 Nm (20 lb in). 13. Install the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). Tighten the screws to 2.3 Nm (20 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5199 Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Replacement (15 Reg Cab With 26 Gal Tank) Fuel Tank Filler Pipe Replacement (15 Reg Cab With 26 Gal Tank) Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle half way. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the fuel tank fill pipe ground wire bolt (3). 6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5200 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1). 8. Open the axle vent hose clip on the fuel fill pipe bracket. 9. Remove the rear axle vent hose from the clip. 10. Disconnect the fuel fill pipe recirculation line quick connect fitting (2) from the evaporative emission (EVAP) rear hose. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 11. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 12. Remove the fuel tank fill pipe. 13. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5201 1. Remove the cap from the opening on the fuel tank. 2. Position the fuel tank fill pipe. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten the clamp to 2.5 Nm (22 lb in). 4. Connect the fuel fill pipe recirculation line quick connect fitting (2) to the EVAP rear hose. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. 6. Close the axle vent hose clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5202 7. Position the chassis harness ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket. 8. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole. 9. Install the fuel tank fill pipe ground wire bolt (3). Tighten the bolt to 9 Nm (80 lb in). 10. Lower the vehicle. 11. Install the fuel tank filler housing. 12. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the screws to 2.3 Nm (20 lb in). 13. Install the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). Tighten the screws to 2.3 Nm (20 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5203 Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tank) Fuel Tank Filler Pipe Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Partially raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the fuel tank fill pipe ground wire bolt (3). 6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5204 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1). 8. Loosen the fuel tank fill pipe clamp (2) at the fuel tank. 9. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 10. Remove the fuel tank fill pipe. 11. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure 1. Remove the cap from the opening on the fuel tank. 2. Install the fuel tank fill pipe. 3. Connect the fuel tank EVAP line quick connect fitting (1) to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the fuel tank fill pipe clamp (2) at the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5205 Tighten the clamp to 2.5 Nm (22 lb in). 5. Position the fuel tank fill pipe ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket. 6. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole. 7. Install the fuel tank fill pipe ground wire bolt (3). Tighten the bolt to 9 Nm (80 lb in). 8. Lower the vehicle. 9. Install the fuel tank filler housing. 10. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the bolts to 2.3 Nm (20 lb in). 11. Install the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5206 Tighten the screws to 2.3 Nm (20 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5207 Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) Fuel Tank Filler Pipe Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Partially raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the fuel tank fill pipe ground wire bolt (3). 6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5208 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1). 8. Loosen the fuel tank fill pipe clamp (2) at the fuel tank. 9. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 10. Remove the fuel tank fill pipe. 11. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure 1. Remove the cap from the opening on the fuel tank. 2. Install the fuel tank fill pipe. 3. Connect the fuel tank EVAP line quick connect fitting (1) to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the fuel tank fill pipe clamp (2) at the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5209 Tighten the clamp to 2.5 Nm (22 lb in). 5. Position the fuel tank fill pipe ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket. 6. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole. 7. Install the fuel tank fill pipe ground wire bolt (3). Tighten the bolt to 9 Nm (80 lb in). 8. Lower the vehicle. 9. Install the fuel tank filler housing. 10. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the bolts to 2.3 Nm (20 lb in). 11. Install the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5210 Tighten the screws to 2.3 Nm (20 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5211 Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Replacement (15 Ext/Crew Cab With 26 Gal Tank) Fuel Tank Filler Pipe Replacement (15 Ext/Crew Cab With 26 Gal Tank) Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle half way. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the fuel tank fill pipe ground wire bolt. 6. Remove the fuel tank fill pipe ground wire anti-rotation tab from the frame hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5212 7. Reposition the fuel tank fill pipe ground wire. 8. Open the axle vent hose clip on the fuel fill pipe bracket. 9. Remove the rear axle vent hose from the clip. 10. If equipped with 5 ft 8 in. bed, perform the following steps: 11. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (2) from the fuel fill pipe recirculation line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 12. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 13. Remove the fuel tank fill pipe. 14. Cap the opening on the fuel tank in order to prevent possible system contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5213 15. If equipped with 6 ft 5 in. bed, perform the following steps: 16. Disconnect the fuel tank EVAP line quick connect fitting (1) from the fuel fill pipe recirculation line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 17. Loosen the fuel tank fill pipe clamp (2) at the fuel tank. 18. Remove the fuel tank fill pipe. 19. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure 1. If equipped with 6 ft 5 in. bed, perform the following steps: 2. Remove the cap from the opening on the fuel tank. 3. Position the fuel tank fill pipe. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the fuel tank fill pipe clamp (2) at the fuel tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5214 Tighten the clamp to 2.5 Nm (22 lb in). 5. Connect the fuel fill pipe recirculation line to the fuel tank EVAP line quick connect fitting (1). Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 6. If equipped with 5 ft 8 in. bed, perform the following steps: 7. Remove the cap from the opening on the fuel tank. 8. Position the fuel tank fill pipe. 9. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten the clamp to 2.5 Nm (22 lb in). 10. Connect the fuel fill pipe recirculation line to the fuel tank EVAP line quick connect fitting (2). Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 11. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5215 12. Close the axle vent hose clip. 13. Position the fuel tank fill pipe ground wire to the frame bracket. 14. Install the fuel tank fill pipe ground wire anti-rotation tab into the frame hole. 15. Install the fuel tank fill pipe ground wire bolt. Tighten the bolt to 9 Nm (80 lb in). 16. Lower the vehicle. 17. Install the fuel tank filler housing. 18. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the screws to 2.3 Nm (20 lb in). 19. Install the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank) > Page 5216 Tighten the screws to 2.3 Nm (20 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair Fuel Filler Neck: Service and Repair Fuel Tank Filler Pipe Housing Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5223 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5224 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5225 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5226 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5227 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5228 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5229 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module (Gas except JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams > Page 5234 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood Fuel Pump Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5239 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5240 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5241 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5242 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5243 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5244 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5245 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5246 Fuel Pump Relay: Locations Harness Routing Views Harness Routing Views Chassis Harness - Front Engine Compartment (31 Series) 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 5247 Fuel Pump Relay: Diagrams Component Connector End Views Fuel Pump Relay - Secondary (LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5251 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5252 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5253 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5254 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5255 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5256 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5257 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5262 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5263 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 2. Remove the accelerator pedal bolts. 3. Remove the accelerator pedal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5264 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5268 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5269 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5270 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5271 Installation Procedure Note: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the MAF/IAT sensor adapter clamp. Tighten the clamp to 4 Nm (35 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams Fuel Pressure Sensor/Switch: Diagrams Component Connector End Views Fuel Pressure Sensor (Gas except LU3 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5275 Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the chassis wiring harness electrical connector (1) from the fuel pressure sensor. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. 4. Remove the fuel pressure sensor from the fuel line. 5. Remove and discard the fuel pressure sensor O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5276 1. Lubricate a NEW fuel pressure sensor O-ring seal with clean engine oil. 2. Install the NEW fuel pressure sensor O-ring seal onto the fuel line fitting. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the fuel pressure sensor to the fuel line. Tighten the sensor to 15 Nm (11 lb ft). 5. Connect the chassis wiring harness electrical connector (1) to the fuel pressure sensor. 6. Lower the vehicle. 7. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5277 4. Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5280 Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the chassis wiring harness electrical connector (1) from the fuel pressure sensor. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. 4. Remove the fuel pressure sensor from the fuel line. 5. Remove and discard the fuel pressure sensor O-ring seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5281 1. Lubricate a NEW fuel pressure sensor O-ring seal with clean engine oil. 2. Install the NEW fuel pressure sensor O-ring seal onto the fuel line fitting. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the fuel pressure sensor to the fuel line. Tighten the sensor to 15 Nm (11 lb ft). 5. Connect the chassis wiring harness electrical connector (1) to the fuel pressure sensor. 6. Lower the vehicle. 7. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5282 4. Inspect for fuel leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Diagrams Throttle Body: Diagrams Component Connector End Views Throttle Body (HP2) Throttle Body (Gas except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Diagrams > Page 5286 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Procedures Throttle Body: Procedures Throttle Body Cleaning 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). Warning Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the throttle blade could cause personal injury. Caution: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. 2. Inspect the throttle body bore and the throttle plate for deposits. You will need to open the throttle plate in order to inspect all surfaces. Caution: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. 3. Clean the throttle body bore and the throttle plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626, or AC-Delco Carburetor Tune-Up Conditioner, P/N X66-P, or an equivalent product. 4. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 5. Perform the Throttle Learn Procedure. Refer to Throttle/Idle Learn (See: Testing and Inspection/Programming and Relearning/Throttle Learn). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Procedures > Page 5289 Throttle Body: Removal and Replacement Throttle Body Assembly Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. Caution: DO NOT for any reason, insert a screwdriver or other small hand tools into the throttle body to hold open the throttle plate, as the wedge inside the throttle body could be damaged. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (3) from the electronic throttle control. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Procedures > Page 5290 3. Remove the throttle body nuts (507) and bolts (538). 4. Remove the throttle body (508). 5. Remove and discard the throttle body gasket (509). Installation Procedure 1. Install a NEW throttle body gasket to the intake manifold. Align the tab of the gasket with the notch in the manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the throttle body (508), bolts (538), and nuts (507) and tighten to 10 Nm (89 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Procedures > Page 5291 Note: Verify that the engine wiring harness electrical connector seal for the electronic throttle control is properly installed and not damaged. 3. Connect the engine wiring harness electrical connector (3) to the electronic throttle control. 4. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. 8. Perform the Throttle Learn Procedure. Refer to Throttle/Idle Learn (See: Testing and Inspection/Programming and Relearning/Throttle Learn). 9. Inspect for coolant leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Ignition System Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5299 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5300 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5301 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5302 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5303 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5304 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement (Except RPOs LY2, LY5, LH6 and LMG) Removal Procedure Note: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the CMP sensor wire harness. 3. Remove the 3 CMP sensor wire harness bolts (738). 4. Disconnect the CMP sensor wire harness electrical connectors from the CMP sensor and the CMP actuator magnet. 5. Remove the CMP sensor wire harness (737). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5305 6. Remove the CMP sensor (703) and O-ring seal (704). Installation Procedure 1. Inspect the CMP O-ring seal for cuts or damage. If the seal is not cut or damaged, it may be used again. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal (704) onto the sensor. 4. Instal the CMP sensor (703) to the front cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5306 5. Install the CMP sensor wire harness (737). 6. Connect the CMP sensor wire harness electrical connectors to the CMP sensor and the CMP actuator magnet. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the 3 CMP sensor wire harness bolts (738). Tighten the bolts to 12 Nm (106 lb in). 8. Connect the engine wiring harness electrical connector (1) to the CMP sensor wire harness. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5310 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5311 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5312 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The Crankshaft Position System Variation Learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * An engine replacement * A engine control module (ECM) replacement * A crankshaft balancer replacement * A crankshaft replacement * A crankshaft position sensor replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The ECM monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position System Variation Learn Procedure. 1. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 2. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 3. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 4. Enable the CKP System Variation Learn Procedure with a scan tool. 5. Quickly apply and release the accelerator pedal. 6. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 7. The scan tool displays Learn Status: Learned this ignition. 8. Once the Learn Procedure has successfully completed, and in order to store the crankshaft position system variation values in the ECM, turn OFF the ignition and verify all vehicle systems are OFF. This may take up to 2 minutes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5313 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure Note: Perform the Crankshaft Position System Variation Learn (See: Testing and Inspection) whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5314 5. Remove the CKP sensor. Installation Procedure 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires, Incorrect routing may cause cross firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for any of the following conditions: * Tearing * Piercing * Arcing * Carbon tracking * Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Page 5318 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Page 5319 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams Ignition Coil: Diagrams Component Connector End Views Ignition Coil 1 (Gas except LU3) Ignition Coil 2 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5323 Ignition Coil 3 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5324 Ignition Coil 4 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5325 Ignition Coil 5 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5326 Ignition Coil 6 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5327 Ignition Coil 7 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5328 Ignition Coil 8 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5329 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5330 Ignition Coil: Testing and Inspection Electronic Ignition System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description This ignition system uses individual ignition module/coil assemblies for each cylinder. The engine control module (ECM) controls the spark events by transmitting the timing pulses on the ignition control (IC) circuits to the individual ignition module/coil assemblies in firing order sequence. Each ignition module/coil has the following circuits: * An ignition 1 voltage circuit * A ground circuit * An IC circuit * A low reference circuit Diagnostic Aids * This test procedure requires that the vehicle battery has passed a load test and is completely charged. * There is an adequate supply of fuel in the fuel tank. * When disconnecting electrical connectors or removing fuses and relays from a fuse block, always inspect both mating electrical terminals for corrosion and terminal tightness. * Use the J 35616 for any test that requires probing the underhood fuse block terminals, component wire harness terminals, or the ECM wire harness terminals. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 26792 Spark Plug Tester * J 35616-A/BT-8637 Connector Test Adapter Kit Circuit/System Verification Observe the Engine Controls Schematic for the ignition module/coils, and review the Ignition System Specifications to verify the following concerns: * The ignition modules/coils are correctly wired and connected * The proper spark plug type Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5331 * The proper spark plug gap and torque * The proper ohm values for the spark plug wires Refer to Ignition System Specifications (See: Specifications). Circuit/System Testing 1. Turn OFF the ignition. Important: This engine application uses 2 fuses, one for each bank, to supply ignition 1 voltage to the ignition module/coil assemblies and also to the fuel injectors. A good indication that a fuse is open is that all 4 misfire counters are incrementing on one side of the engine 2. Inspect both fuses that supply ignition voltage to the ignition module/coils. ‹› If a fuse is open, test all 8 ignition voltage circuits to the ignition module/coils or the fuel injectors on that engine bank, for a short to ground. 3. Disconnect the 4 ignition module/coil, and the 4 fuel injector electrical connectors, for the engine bank that has the open fuse. 4. Replace the open fuse with a new fuse. 5. Ignition ON, engine OFF. 6. Reconnect each ignition module/coil, and fuel injector electrical connectors, one at a time. ‹› If the fuse opens when connecting an ignition module/coil or fuel injector electrical connector, then replace the component that caused the fuse to open. 7. Ignition OFF, disconnect the appropriate ignition module/coil electrical connector. 8. Ignition ON, verify that a test lamp illuminates between the ignition voltage circuit and ground. ‹› If the test lamp does not illuminate test the ignition voltage circuit for an open/high resistance. 9. Verify that a test lamp illuminates between the ignition module/coil ground circuit and B+. ‹› If the test lamp does not illuminate, test the ignition module/coil ground circuit for an open/high resistance. 10. Inspect and measure the resistance of the spark plug wire. Refer to Spark Plug Wire Inspection (See: Ignition Cable/Testing and Inspection) and Ignition System Specifications (See: Specifications). ‹› If the resistance value is not within the specified range, or does not pass the inspection, replace the spark plug wire. 11. Exchange the misfiring cylinder, ignition module/coil assembly with the ignition module/coil assembly from a non-misfiring cylinder. 12. Start and idle the engine. Observe the misfire counters on the scan tool. ‹› If the misfire transfers with the suspect ignition module/coil, then replace the ignition module/coil assembly. ‹› If the misfire does not transfer with the suspect ignition module/coil, then measure the resistance of the IC circuit. The IC circuit should measure less than 5 ohms. If the circuit tests normal, replace the ECM. Component Testing * Use the Spark Plug Inspection procedure to verify the integrity of the spark plugs. Refer to Spark Plug Inspection (See: Spark Plug/Testing and Inspection). Replace the spark plug if necessary. Important: An erratic or weak spark is considered a no spark condition. * Use the J 26792 to verify the output of each ignition module/coil. If no spark is detected across the gap of the spark plug tester, then replace the ignition module/coil assembly. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Engine Control Module Programming and Setup (RPO LMM) (See: Testing and Inspection/Programming and Relearning/Engine Control Module Programming and Setup)Engine Control Module Programming and Setup (Gasoline Engines) (See: Testing and Inspection/Programming and Relearning/Engine Control Module Programming and Setup) * Engine Control Module Replacement (See: Computers and Control Systems/Engine Control Module/Service and Repair) * Ignition Coil Replacement (See: Service and Repair) * Spark Plug Replacement (See: Spark Plug/Service and Repair) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5332 Ignition Coil: Service and Repair Ignition Coil Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 2. Disconnect the ignition coil wiring harness electrical connector (1) from the ignition coil. 3. Remove the spark plug wire from the ignition coil. * Twist the spark plug wire boot a 1/2 turn. * Pull only on the boot in order to remove the wire from the ignition coil. 4. Remove the ignition coil bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5333 5. Remove the ignition coil from the bracket. (left side shown, right side similar). 6. There are 2 different manufacturers for the ignition coils and coil brackets. They are as follows: 7. The Melco(R) (1) ignition coil is a square design. 8. The Delphi(R) (2) ignition coil is a round design. 9. The Melco(R) ignition coil bracket (1) is a square design. 10. The Delphi(R) ignition coil bracket (2) is a round design. Installation Procedure 1. Position the ignition coil to the ignition coil bracket. (left side shown, right side similar). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5334 2. Install the ignition coil bolts. Tighten the bolts to 10 Nm (89 lb in). 3. Install the spark plug wire to the ignition coil. 4. Inspect the spark plug wire for proper installation: * Push sideways on each boot in order the inspect the seating. * Reinstall any loose boot. 5. Connect the ignition coil wiring harness electrical connector (1) to the ignition coil. 6. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams Ignition Control Module: Diagrams Component Connector End Views Ignition Control Module (ICM) (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 5341 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 5344 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (4) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 5345 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 5346 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (2) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams Ignition Control Module: Diagrams Component Connector End Views Ignition Control Module (ICM) (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5355 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5356 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5357 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5358 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5359 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5360 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement (Except RPOs LY2, LY5, LH6 and LMG) Removal Procedure Note: Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the CMP sensor wire harness. 3. Remove the 3 CMP sensor wire harness bolts (738). 4. Disconnect the CMP sensor wire harness electrical connectors from the CMP sensor and the CMP actuator magnet. 5. Remove the CMP sensor wire harness (737). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5361 6. Remove the CMP sensor (703) and O-ring seal (704). Installation Procedure 1. Inspect the CMP O-ring seal for cuts or damage. If the seal is not cut or damaged, it may be used again. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal (704) onto the sensor. 4. Instal the CMP sensor (703) to the front cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5362 5. Install the CMP sensor wire harness (737). 6. Connect the CMP sensor wire harness electrical connectors to the CMP sensor and the CMP actuator magnet. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the 3 CMP sensor wire harness bolts (738). Tighten the bolts to 12 Nm (106 lb in). 8. Connect the engine wiring harness electrical connector (1) to the CMP sensor wire harness. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5366 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5367 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5368 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The Crankshaft Position System Variation Learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * An engine replacement * A engine control module (ECM) replacement * A crankshaft balancer replacement * A crankshaft replacement * A crankshaft position sensor replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The ECM monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position System Variation Learn Procedure. 1. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 2. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 3. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 4. Enable the CKP System Variation Learn Procedure with a scan tool. 5. Quickly apply and release the accelerator pedal. 6. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 7. The scan tool displays Learn Status: Learned this ignition. 8. Once the Learn Procedure has successfully completed, and in order to store the crankshaft position system variation values in the ECM, turn OFF the ignition and verify all vehicle systems are OFF. This may take up to 2 minutes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5369 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure Note: Perform the Crankshaft Position System Variation Learn (See: Testing and Inspection) whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5370 5. Remove the CKP sensor. Installation Procedure 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Install the starter. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 5. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 5376 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 5377 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note: The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 5378 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5382 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 5385 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (4) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 5386 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor 1 Replacement > Page 5387 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft) 2. Connect the engine wiring harness electrical connector (2) to knock sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Ignition System Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5391 Spark Plug: Application and ID Ignition System Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5392 Spark Plug: Testing and Inspection Spark Plug Inspection * Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling, replace with a colder plug - Pre-ignition causing spark plug and/or engine damage , replace with a hotter plug * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. * Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5393 * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications (See: Specifications). An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Specifications). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection * Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak ignition coils * Worn ignition wires * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5394 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 2. Brush or using compressed air, blow away any dirt from around the spark plug. 3. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5395 1. Inspect the spark plug gap. Adjust the gap as needed. Refer to Ignition System Specifications (See: Specifications). 2. Hand start the spark plug in the corresponding cylinder. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the spark plug to 15 Nm (11 lb ft). 4. Install the spark plug wire to the spark plug. 5. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5402 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 5406 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5411 Shift Solenoid: Specifications 6L45/6L50/6L80/6L90 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5412 Shift Solenoid: Locations Disassembled Views Control Valve Body Assembly (1 of 2) 350 - Control Valve Body Assembly 353 - Forward Accumulator Oil Seal 354 - Forward Accumulator Piston 355 - Forward Accumulator Pin 356 - Forward Accumulator Spring 357 Forward Abuse Valve 358 - Forward Abuse Valve Spring 359 - Bore Plug 360 - Coiled Spring Pin 360 - Coiled Spring Pin 361 - Low Overrun Valve 362 - Low Overrun Valve Spring 363 - Forward Accumulator Cover 364 - Forward Accumulator Cover Bolt 364a - Pressure Control Solenoid Retainer Bolt 365 - 1-2 Shift Valve Spring - Model Dependent 366 - 1-2 Shift Valve - Model Dependent 367a - 1-2 Shift Solenoid Valve 367b - 2-3 Shift Solenoid Valve 368 - 2-3 Shift Valve 369 - 2-3 Shuttle Valve 370 - 1-2 Accumulator Valve Spring 371 - 1-2 Accumulator Valve 372 - 1-2 Accumulator Valve Sleeve 374 - Actuator Feed Limit Valve 375 - Actuator Feed Limit Valve Spring 376 - Bore Plug 377 - Pressure Control Solenoid Valve Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5413 378 - Pressure Control Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5416 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5417 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5418 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5419 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5420 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5421 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5422 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5423 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5424 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5425 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5426 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5427 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5428 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5429 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5444 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5445 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5446 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5447 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5448 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5449 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5450 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5451 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5452 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5453 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5454 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5455 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5456 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5457 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5458 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5459 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5460 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5461 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5462 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5463 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5464 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5479 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5480 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5481 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5482 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5483 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5484 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5485 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5486 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5487 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5488 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5489 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5490 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5491 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5492 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5493 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5494 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5495 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5496 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5497 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5514 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5515 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5516 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5517 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5518 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5519 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5520 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5521 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5522 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5523 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5524 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5525 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5526 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5527 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5528 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5529 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5530 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5531 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5532 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5533 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5534 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5535 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5536 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5558 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5559 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5560 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5561 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5562 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5563 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5564 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5565 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5566 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5567 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5568 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5569 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5570 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5571 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5572 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5573 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5574 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5575 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5576 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5577 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5578 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5579 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5580 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5581 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5582 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5583 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5584 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5585 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5586 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5587 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5588 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5589 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5590 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5591 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5592 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5593 Shift Solenoid: Connector Views Component Connector End Views Control Solenoid Valve Assembly X1 (MYC, MYD or M99) Control Solenoid Valve Assembly X2 (MYC, MYD or M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5594 Control Solenoid Valve Assembly X3 (MYC, MYD or M99) 1-2 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5595 2-3 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5596 Shift Solenoid (SS) Valve 1 (MW7) Shift Solenoid (SS) Valve 2 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5597 Shift Solenoid (SS) Valve 3 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Note: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Accumulator/Service and Repair). 3. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5600 4. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). 5. Remove the pressure control solenoid (377). Note the orientation upon removal. 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. Installation Procedure Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 1. Install the 1-2 and 2-3 shift solenoids. 2. Install the 1-2 and 2-3 shift solenoid retainers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5601 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 lb in) 4. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 5. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Accumulator/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5602 6. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 7. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 8. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Description and Operation/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Adaptive Functions (TCM)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5603 Shift Solenoid: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5604 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5609 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5610 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5611 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5612 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5613 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5614 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5615 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5616 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5617 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5618 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5619 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5620 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5621 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5622 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5623 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5624 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5625 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5626 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5627 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5628 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5629 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5630 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5631 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5632 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5633 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5634 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5635 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5636 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5637 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5638 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5639 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5640 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5641 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5642 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5643 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5644 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5645 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5646 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5647 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5648 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5649 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5650 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5651 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5652 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5653 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5654 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5655 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5656 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5660 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5661 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5662 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5663 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5664 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5665 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5666 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5667 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5668 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5669 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5670 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5671 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5672 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5673 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5674 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5675 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5676 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5677 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5678 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5679 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5680 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5681 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5682 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5683 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5684 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5685 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5686 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5687 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5688 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5689 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5690 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5691 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5692 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5693 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5694 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5695 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5696 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5697 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5698 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5699 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5700 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5701 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5702 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5703 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5704 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5705 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5706 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5707 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5708 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5709 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5710 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5711 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5712 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5713 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5714 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5715 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5716 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5717 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5718 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5719 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5720 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5721 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5722 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5723 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5724 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5726 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5736 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5737 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5738 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5739 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5740 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5741 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5742 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5743 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5744 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5745 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5746 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5747 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5748 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5749 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5750 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5751 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5752 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5753 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5754 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5755 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5756 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5757 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5758 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5759 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5760 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5761 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5762 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5763 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5764 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5765 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5766 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5767 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5768 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5783 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5784 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5785 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5786 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5787 Torque Converter Clutch (TCC) Solenoid Valve (M30) Wiring Diagram Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5788 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and Wiring Harness Special Tools J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and the filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 3. Disconnect the transmission harness 20 way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up. Do not pry the connector. Note: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Accumulator/Service and Repair). 5. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5789 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the TCC solenoid bolts (68). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5790 9. Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so the wiring harness hangs down. 10. Remove the solenoid retainer bolt (36A) and the solenoid retainer (378). 11. Remove the pressure control solenoid (377). Note the orientation upon removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5791 12. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. 13. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the 4 tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 14. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly (66) from the transmission case. 15. Inspect the TCC solenoid and wiring harness assembly for the following defects: * Damage * Cracked connectors * Exposed wires * Loose pins Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5792 1. Install the wiring harness and TCC solenoid assembly (66) with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. 1. Tighten the control valve body retaining bolts to 11 Nm (97 lb in). 2. Tighten the TCC solenoid retaining bolts to 11 Nm (97 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5793 Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 4. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. The solenoid retainer bolt (364) Tighten the solenoid retainer bolt to 11 Nm (97 lb in) 5. Install the TCC PWM solenoid to the control valve body. 6. Install the TCC PWM solenoid retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5794 7. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 8. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Accumulator/Service and Repair). 9. Connect the transmission harness 20 way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 10. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 11. Lower the vehicle. 12. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 13. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Description and Operation/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Adaptive Functions (TCM)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair Actuator: Service and Repair Front Drive Axle Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Disconnect the electrical connector from the actuator. 4. Remove the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.5 inch axle (4) by turning the actuator counterclockwise. Installation Procedure 1. Apply sealant to the threads of the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.25 inch axle (4). Use the correct sealant. Refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 5799 Adhesives, Fluids, Lubricants, and Sealers (See: Maintenance/Fluids/Fluid Differential/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the actuator (1 or 3). Tighten the actuator to 20 Nm (15 lb ft). 3. Connect the electrical connector to the actuator. 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams Transfer Case Actuator: Diagrams Component Connector End Views Transfer Case Encoder Motor (NQF or NQH) Front Drive Axle Actuator (NQF, NQG or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 5804 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Transfer Case Actuator: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 5807 Transfer Case Actuator: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 5808 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5819 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5820 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5821 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5827 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5828 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5829 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 5830 Control Module: Locations Harness Routing Views Engine Chassis Harness Routing - Top Front (Diesel) 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 5831 Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 5832 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 5833 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 5834 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 5835 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Power Take-Off > Power Take-Off Relay > Component Information > Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF or NQH) Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 5844 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 5845 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 5848 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5865 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5866 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5867 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5873 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5874 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5875 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 5876 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5885 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5886 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5887 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5893 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5894 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5895 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 5896 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Parking Lock and Manual Shift Detent Lever with Shaft Position Switch Assembly 78 - Steel Cup Plug 79 - Parking Brake Pawl Shaft 80 - Parking Pawl Return Spring 81 - Parking Brake Pawl 82 - Manual Shaft Seal 84 - Manual Shaft - Model Dependent 85 - Parking Lock Actuator Assembly 86 - Parking Lock Bracket 87 - Parking Lock Bracket Bolt 88 - Manual Shift Detent Lever with Shaft Position Switch Assembly 89 - Manual Valve Link 92 - Manual Shift Detent Lever Hub Pin Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5901 Transmission Position Switch/Sensor: Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5902 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5905 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5906 Transmission Position Switch/Sensor: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 Nm (9 lb ft). 3. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Install the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5907 Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5912 Transmission Position Switch/Sensor: Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5913 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5916 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5917 Transmission Position Switch/Sensor: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 Nm (9 lb ft). 3. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Install the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 5918 Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Speed Sensor: Component Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 5923 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Oil Pump Assembly 200 - Pump Body 201 - Oil Seal Ring - Slide to Wear Plate 202 - O-Ring Seal - Slide Seal Back-Up 203 - Pump Slide 204 - Pivot Pin Spring 205 - Pivot Slide Pin 208 - Pump Slide Seal Support 209 Pump Slide Seal 210 - Pump Vane Ring 210 - Pump Vane Ring 211 - Rotor Guide 212 - Oil Pump Rotor 213 - Pump Vane 214 - Stator Shaft 215 - Pump Cover 216 - Pressure Regulator Valve Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 5924 217 - Pressure Regulator Valve Spring 218 - Pressure Regulator Isolator Spring 219 - Reverse Boost Valve 220 - Reverse Boost Valve Sleeve 221 - Oil Pump Reverse Boost Valve Retaining Ring 222 - Oil Pump Converter Clutch Valve Retaining Ring 223 - Stop Valve 224 - Converter Clutch Valve - Model Dependent 227 - Pressure Relief Bolt Rivet 228 - Pressure Relief Ball 229 Pressure Relief Spring 230 - Oil Seal Ring - Stator Shaft 231 - Oil Pump Cover Screen Seal 232 Oil Pump Cover Screen 233 - Bolt M8 X 1.25 X 40 - Cover to Body 234 - Stator Shaft Bushing Front 235 - Oil Pump Cover Plug - FWD Clutch Feed 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 237 - Check Valve Retainer and Ball Assembly 237 - Check Valve Retainer and Ball Assembly 238 - Converter Clutch Signal Orifice - Cup Plug 240 - Cup Orifice Plug 241 Stator Shaft Bushing - Rear 242 - Pump Body Bushing 243 - Oil Seal Assembly 244 - Fluid Seal Retainer 245 - A/T Fluid Pump Slide Outer Spring 246 - Converter Clutch Valve Spring 247 - A/T ISS Attaching Bolt - Model Dependent 249 - O-ring 250 - A/T Input Speed Sensor (ISS) Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 5925 Transmission Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5926 Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5927 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5928 Transmission Speed Sensor: Service and Repair Input and Output Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 5933 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Oil Pump Assembly 200 - Pump Body 201 - Oil Seal Ring - Slide to Wear Plate 202 - O-Ring Seal - Slide Seal Back-Up 203 - Pump Slide 204 - Pivot Pin Spring 205 - Pivot Slide Pin 208 - Pump Slide Seal Support 209 Pump Slide Seal 210 - Pump Vane Ring 210 - Pump Vane Ring 211 - Rotor Guide 212 - Oil Pump Rotor 213 - Pump Vane 214 - Stator Shaft 215 - Pump Cover 216 - Pressure Regulator Valve Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 5934 217 - Pressure Regulator Valve Spring 218 - Pressure Regulator Isolator Spring 219 - Reverse Boost Valve 220 - Reverse Boost Valve Sleeve 221 - Oil Pump Reverse Boost Valve Retaining Ring 222 - Oil Pump Converter Clutch Valve Retaining Ring 223 - Stop Valve 224 - Converter Clutch Valve - Model Dependent 227 - Pressure Relief Bolt Rivet 228 - Pressure Relief Ball 229 Pressure Relief Spring 230 - Oil Seal Ring - Stator Shaft 231 - Oil Pump Cover Screen Seal 232 Oil Pump Cover Screen 233 - Bolt M8 X 1.25 X 40 - Cover to Body 234 - Stator Shaft Bushing Front 235 - Oil Pump Cover Plug - FWD Clutch Feed 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 237 - Check Valve Retainer and Ball Assembly 237 - Check Valve Retainer and Ball Assembly 238 - Converter Clutch Signal Orifice - Cup Plug 240 - Cup Orifice Plug 241 Stator Shaft Bushing - Rear 242 - Pump Body Bushing 243 - Oil Seal Assembly 244 - Fluid Seal Retainer 245 - A/T Fluid Pump Slide Outer Spring 246 - Converter Clutch Valve Spring 247 - A/T ISS Attaching Bolt - Model Dependent 249 - O-ring 250 - A/T Input Speed Sensor (ISS) Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 5935 Transmission Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5936 Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5937 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5938 Transmission Speed Sensor: Service and Repair Input and Output Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 5942 Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 5945 Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection Clutch Pedal Position Sensor Learn Important: The clutch pedal position (CPP) sensor learn procedure is required when the following service procedures have been performed regardless of whether DTC P080A is set: * An engine control module (ECM) replacement * A CPP sensor replacement * Any repairs which affect the CPP sensor relationship 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P080A, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select Clutch Pedal Position Learn under Module Setup in Manual Transmission, and perform the following instructions displayed on the scan tool screen. Important: The CPP sensor learn procedure cannot be performed more than once per ignition cycle. The clutch pedal needs to be fully depressed and held steady throughout this procedure in order to perform a correct learning. 4. The scan tool will display under CPP Learn Status: Not Learned, In Process, Complete, Fail Low Volt, Fail - High Volt, or Fail Moving. The scan tool will display under CPP Learn Status Complete if the process was successful. 5. If the scan tool indicates that DTC P080A ran and passed this ignition the CPP sensor learn procedure is complete. If the scan tool indicates DTC P080A failed or did not run this ignition, refer to DTC P080A (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission). If any other DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List Vehicle) for the applicable DTC. 6. Turn OFF the ignition for 30 seconds after the learn procedure has successfully completed in order to store the CPP sensor variation values in ECM history. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 5950 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Engine Start Switch Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Remove the plastic retainer (1) tabs from the clutch pedal position switch (2). 3. Remove the clutch pedal position switch (2) from the pushrod. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 5951 1. Install the clutch pedal position switch (2) to the pushrod. 2. Install the plastic retainer (1) tabs to the clutch pedal position switch (2). 3. Connect the clutch pedal position switch electrical connector (1). Warning Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged. 4. Perform the clutch pedal position sensor learn procedure. Refer to DTC P080A (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission) or Clutch Pedal Position Sensor Learn (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Harness Routing Views Engine Harness Routing - Rear (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Dash Panel 2 - Transmission 3 - X175 (M30) 4 - Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5960 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF or NQH) Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5961 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 5964 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 5965 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 5966 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Page 5973 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the speed sensor with a NEW O-ring. Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels PROM - Programmable Read Only Memory: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON PROM - Programmable Read Only Memory: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5986 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5987 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5988 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 5994 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 5995 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 5996 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels PROM - Programmable Read Only Memory: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6005 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6006 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6007 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6012 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6013 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6014 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6020 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6021 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6022 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6027 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6028 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-06-04-026B > Apr > 10 > Engine/Transmission - Aftermarket Calibrations > Page 6029 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6036 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 6040 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E Automatic Transmission Shift Solenoid: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 6045 Shift Solenoid: Specifications 6L45/6L50/6L80/6L90 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 6046 Shift Solenoid: Locations Disassembled Views Control Valve Body Assembly (1 of 2) 350 - Control Valve Body Assembly 353 - Forward Accumulator Oil Seal 354 - Forward Accumulator Piston 355 - Forward Accumulator Pin 356 - Forward Accumulator Spring 357 Forward Abuse Valve 358 - Forward Abuse Valve Spring 359 - Bore Plug 360 - Coiled Spring Pin 360 - Coiled Spring Pin 361 - Low Overrun Valve 362 - Low Overrun Valve Spring 363 - Forward Accumulator Cover 364 - Forward Accumulator Cover Bolt 364a - Pressure Control Solenoid Retainer Bolt 365 - 1-2 Shift Valve Spring - Model Dependent 366 - 1-2 Shift Valve - Model Dependent 367a - 1-2 Shift Solenoid Valve 367b - 2-3 Shift Solenoid Valve 368 - 2-3 Shift Valve 369 - 2-3 Shuttle Valve 370 - 1-2 Accumulator Valve Spring 371 - 1-2 Accumulator Valve 372 - 1-2 Accumulator Valve Sleeve 374 - Actuator Feed Limit Valve 375 - Actuator Feed Limit Valve Spring 376 - Bore Plug 377 - Pressure Control Solenoid Valve Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 6047 378 - Pressure Control Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6050 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6051 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6052 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6053 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6054 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6055 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6056 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6057 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6058 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6059 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6060 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6061 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6062 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6063 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6064 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6065 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6066 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6067 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6068 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6069 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6070 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6071 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6072 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6073 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6074 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6075 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6076 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6077 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6078 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6079 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6080 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6081 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6082 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6083 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6084 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6085 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6086 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6087 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6088 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6089 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6090 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6091 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6092 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6093 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6094 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6095 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6097 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6098 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6099 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6100 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6101 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6102 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6104 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6105 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6106 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6107 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6108 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6109 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6110 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6111 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6112 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6113 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6114 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6115 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6116 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6117 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6118 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6121 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6122 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6123 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6124 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6125 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6126 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6127 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6128 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6129 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6137 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6144 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6147 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6148 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6149 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6150 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6151 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6152 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6153 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6154 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6155 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6156 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6157 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6158 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6159 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6160 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6161 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6162 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6163 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6164 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6165 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6166 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6167 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6168 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6169 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6170 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6171 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6172 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6173 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6174 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6175 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6176 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6177 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6178 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6179 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6180 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6181 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6182 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6183 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6184 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6185 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6186 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6187 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6188 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6189 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6190 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6191 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6192 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6193 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6194 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6195 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6196 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6197 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6198 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6199 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6200 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6201 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6202 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6203 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6204 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6205 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6206 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6207 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6208 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6209 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6210 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6211 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6212 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6213 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6214 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6215 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6216 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6217 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6218 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6219 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6220 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6221 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6222 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6223 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6224 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6225 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6226 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6227 Shift Solenoid: Connector Views Component Connector End Views Control Solenoid Valve Assembly X1 (MYC, MYD or M99) Control Solenoid Valve Assembly X2 (MYC, MYD or M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6228 Control Solenoid Valve Assembly X3 (MYC, MYD or M99) 1-2 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6229 2-3 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6230 Shift Solenoid (SS) Valve 1 (MW7) Shift Solenoid (SS) Valve 2 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6231 Shift Solenoid (SS) Valve 3 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Note: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). 3. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6234 4. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). 5. Remove the pressure control solenoid (377). Note the orientation upon removal. 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. Installation Procedure Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 1. Install the 1-2 and 2-3 shift solenoids. 2. Install the 1-2 and 2-3 shift solenoid retainers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6235 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 lb in) 4. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 5. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6236 6. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 7. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 8. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM) (See: Automatic Transmission/Transaxle/Description and Operation/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Adaptive Functions (TCM)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6237 Shift Solenoid: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6238 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6243 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6244 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6245 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6246 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6247 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6248 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6249 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6250 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6251 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6252 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6253 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6254 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6255 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6256 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6257 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6258 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6259 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6260 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6261 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6262 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6263 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6264 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6265 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6266 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6267 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6268 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6269 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6270 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6271 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6272 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6273 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6274 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6275 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6276 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6277 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6278 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6279 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6280 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6281 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6282 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6283 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6284 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6285 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6286 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6287 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6288 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6289 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6290 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6291 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6292 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6293 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6294 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6295 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6296 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6297 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6298 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6299 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6300 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6301 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6302 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6303 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6304 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6305 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6306 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6307 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6308 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6309 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6310 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6311 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6312 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6313 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6314 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6315 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6316 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6317 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6318 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6319 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6320 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6321 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6322 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6323 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6324 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6325 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6326 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6327 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6328 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6329 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6330 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6331 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6332 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6333 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6334 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6335 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6336 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6337 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6338 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6339 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6340 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6341 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6342 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6343 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6344 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6345 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6346 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6347 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6348 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6349 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6350 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6351 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6352 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6353 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6354 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6355 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6356 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6357 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6358 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6359 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6360 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6361 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6362 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6364 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6366 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6369 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6370 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6371 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6372 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6373 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6374 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6375 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6376 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6377 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6378 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6379 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6380 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6381 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6382 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6383 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6384 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6385 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6386 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6387 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6388 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6389 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6390 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6391 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6392 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6393 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6394 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6395 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6396 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6397 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6398 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6399 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6400 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6404 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6405 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6406 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6407 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6408 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6409 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6410 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6411 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6412 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6413 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6414 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6415 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6416 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6417 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6418 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6419 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6420 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6421 Torque Converter Clutch (TCC) Solenoid Valve (M30) Wiring Diagram Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6422 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and Wiring Harness Special Tools J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and the filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 3. Disconnect the transmission harness 20 way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up. Do not pry the connector. Note: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). 5. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6423 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the TCC solenoid bolts (68). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6424 9. Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so the wiring harness hangs down. 10. Remove the solenoid retainer bolt (36A) and the solenoid retainer (378). 11. Remove the pressure control solenoid (377). Note the orientation upon removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6425 12. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. 13. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the 4 tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 14. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly (66) from the transmission case. 15. Inspect the TCC solenoid and wiring harness assembly for the following defects: * Damage * Cracked connectors * Exposed wires * Loose pins Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6426 1. Install the wiring harness and TCC solenoid assembly (66) with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. 1. Tighten the control valve body retaining bolts to 11 Nm (97 lb in). 2. Tighten the TCC solenoid retaining bolts to 11 Nm (97 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6427 Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 4. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. The solenoid retainer bolt (364) Tighten the solenoid retainer bolt to 11 Nm (97 lb in) 5. Install the TCC PWM solenoid to the control valve body. 6. Install the TCC PWM solenoid retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6428 7. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 8. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). 9. Connect the transmission harness 20 way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 10. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 11. Lower the vehicle. 12. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 13. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM) (See: Automatic Transmission/Transaxle/Description and Operation/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Adaptive Functions (TCM)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair Actuator: Service and Repair Front Drive Axle Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Disconnect the electrical connector from the actuator. 4. Remove the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.5 inch axle (4) by turning the actuator counterclockwise. Installation Procedure 1. Apply sealant to the threads of the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.25 inch axle (4). Use the correct sealant. Refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 6433 Adhesives, Fluids, Lubricants, and Sealers (See: Differential Assembly/Fluid Differential/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the actuator (1 or 3). Tighten the actuator to 20 Nm (15 lb ft). 3. Connect the electrical connector to the actuator. 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams Transfer Case Actuator: Diagrams Component Connector End Views Transfer Case Encoder Motor (NQF or NQH) Front Drive Axle Actuator (NQF, NQG or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 6438 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Transfer Case Actuator: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 6441 Transfer Case Actuator: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 6442 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6448 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 6452 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6457 Shift Solenoid: Specifications 6L45/6L50/6L80/6L90 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 6458 Shift Solenoid: Locations Disassembled Views Control Valve Body Assembly (1 of 2) 350 - Control Valve Body Assembly 353 - Forward Accumulator Oil Seal 354 - Forward Accumulator Piston 355 - Forward Accumulator Pin 356 - Forward Accumulator Spring 357 Forward Abuse Valve 358 - Forward Abuse Valve Spring 359 - Bore Plug 360 - Coiled Spring Pin 360 - Coiled Spring Pin 361 - Low Overrun Valve 362 - Low Overrun Valve Spring 363 - Forward Accumulator Cover 364 - Forward Accumulator Cover Bolt 364a - Pressure Control Solenoid Retainer Bolt 365 - 1-2 Shift Valve Spring - Model Dependent 366 - 1-2 Shift Valve - Model Dependent 367a - 1-2 Shift Solenoid Valve 367b - 2-3 Shift Solenoid Valve 368 - 2-3 Shift Valve 369 - 2-3 Shuttle Valve 370 - 1-2 Accumulator Valve Spring 371 - 1-2 Accumulator Valve 372 - 1-2 Accumulator Valve Sleeve 374 - Actuator Feed Limit Valve 375 - Actuator Feed Limit Valve Spring 376 - Bore Plug 377 - Pressure Control Solenoid Valve Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 6459 378 - Pressure Control Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6462 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6463 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6464 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6465 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6466 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6467 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6468 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6469 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6470 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6471 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6472 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6473 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6474 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6475 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6476 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6477 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6478 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6479 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6480 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6481 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6482 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6483 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6484 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6485 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6486 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6487 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6488 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6489 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6490 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6491 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6492 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6493 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6494 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6495 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6496 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6497 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6498 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6499 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6500 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6501 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6502 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6503 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6504 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6505 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6506 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6507 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6508 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6509 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6510 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6511 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6512 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6513 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6514 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6515 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6516 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6517 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6518 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6519 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6520 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6521 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6522 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6523 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6524 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6525 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6526 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6527 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6528 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6529 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6530 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6531 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6532 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6533 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6534 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6535 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6536 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6537 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6538 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6539 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6540 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6541 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6542 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6543 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6544 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6545 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6546 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6547 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6548 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6549 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6550 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6551 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6552 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6553 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6554 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6555 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6556 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6557 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6558 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6559 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6560 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6561 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6562 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6563 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6564 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6565 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6566 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6567 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6568 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6569 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6570 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6571 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6572 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6573 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6574 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6575 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6576 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6577 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6578 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6579 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6580 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6581 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6582 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6583 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6584 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6585 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6586 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6587 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6588 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6589 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6590 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6591 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6592 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6593 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6594 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6595 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6596 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6597 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6598 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6599 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6600 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6601 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6602 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6603 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6604 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6605 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6606 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6607 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6608 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6609 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6610 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6611 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6612 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6613 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6614 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6615 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6616 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6617 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6618 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6619 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6620 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6621 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6622 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6623 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6624 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6625 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6626 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6627 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6628 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6629 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6630 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6631 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6632 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6633 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6634 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6635 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6636 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6637 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6638 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6639 Shift Solenoid: Connector Views Component Connector End Views Control Solenoid Valve Assembly X1 (MYC, MYD or M99) Control Solenoid Valve Assembly X2 (MYC, MYD or M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6640 Control Solenoid Valve Assembly X3 (MYC, MYD or M99) 1-2 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6641 2-3 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6642 Shift Solenoid (SS) Valve 1 (MW7) Shift Solenoid (SS) Valve 2 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6643 Shift Solenoid (SS) Valve 3 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Note: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 3. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6646 4. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). 5. Remove the pressure control solenoid (377). Note the orientation upon removal. 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. Installation Procedure Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 1. Install the 1-2 and 2-3 shift solenoids. 2. Install the 1-2 and 2-3 shift solenoid retainers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6647 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 lb in) 4. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 5. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 6. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 7. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6648 Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 8. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM) (See: Description and Operation/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Adaptive Functions (TCM)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6649 Shift Solenoid: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6650 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6655 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6656 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6657 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6658 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6659 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6660 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6661 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6662 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6663 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6664 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6665 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6666 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6667 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6668 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6669 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6670 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6671 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6672 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6673 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6674 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6675 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6676 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6677 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6679 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6680 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6681 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6682 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6683 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6684 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6686 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6687 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6688 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6689 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6690 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6691 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6692 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6693 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6694 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6695 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6696 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6697 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6698 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6699 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6700 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6701 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6702 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6703 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6704 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6705 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6706 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6707 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6708 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6709 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6710 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6748 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6749 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6750 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6751 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6780 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6781 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6782 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6783 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6784 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6785 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6786 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6791 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6792 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6793 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6794 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6795 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6796 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6797 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6798 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6799 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6808 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6809 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6810 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6814 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6815 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6816 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6817 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6818 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6819 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6820 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6821 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6822 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6823 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6824 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6825 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6826 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6827 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6828 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6829 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6830 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6831 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6832 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6833 Torque Converter Clutch (TCC) Solenoid Valve (M30) Wiring Diagram Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6834 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and Wiring Harness Special Tools J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and the filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 3. Disconnect the transmission harness 20 way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up. Do not pry the connector. Note: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 5. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6835 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the TCC solenoid bolts (68). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6836 9. Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so the wiring harness hangs down. 10. Remove the solenoid retainer bolt (36A) and the solenoid retainer (378). 11. Remove the pressure control solenoid (377). Note the orientation upon removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6837 12. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. 13. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the 4 tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 14. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly (66) from the transmission case. 15. Inspect the TCC solenoid and wiring harness assembly for the following defects: * Damage * Cracked connectors * Exposed wires * Loose pins Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6838 1. Install the wiring harness and TCC solenoid assembly (66) with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. 1. Tighten the control valve body retaining bolts to 11 Nm (97 lb in). 2. Tighten the TCC solenoid retaining bolts to 11 Nm (97 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6839 Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 4. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. The solenoid retainer bolt (364) Tighten the solenoid retainer bolt to 11 Nm (97 lb in) 5. Install the TCC PWM solenoid to the control valve body. 6. Install the TCC PWM solenoid retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6840 7. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 8. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 9. Connect the transmission harness 20 way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 10. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 11. Lower the vehicle. 12. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 13. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM) (See: Description and Operation/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Adaptive Functions (TCM)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair Accumulator: Service and Repair Accumulator Assembly, Spacer Plate, and Gaskets Special Tools * J 25025-B Pump and Valve Body Alignment Pin Set * J 36850 Transjel Lubricant Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Note: The 1-2 accumulator can be removed without removing the control valve assembly. 3. Remove the control valve body. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair/4L60-E/4L65-E/4L70-E Automatic Transmission). 4. Remove the accumulator cover retaining bolts. 5. Remove the 1-2 accumulator cover assembly. 6. Disassemble the 1-2 accumulator. Refer to 1-2 Accumulator Disassemble (See: Service and Repair/Overhaul/4L60-E/4L65-E/4L70-E Automatic Transmission/76. 1-2 Accumulator Disassemble). 7. Remove the spacer plate support retaining bolts (77). Note: Use care not to drop the following items that will be removed along with the spacer plate: * The number 1 checkball * The 3-4 accumulator spring Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 6844 * The 3-4 accumulator pin 8. Remove the spacer plate support (53 or 113). Note: Do not reuse the bonded spacer plate. Replace with a NEW bonded spacer plate. 9. Remove the bonded valve body spacer plate (48), discard, do not reuse. 10. Remove the 3-4 accumulator piston (2). Note: Some models do not use a 3-4 accumulator spring. 11. Inspect the 3-4 accumulator spring for cracks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 6845 12. Remove the 3-4 accumulator piston seal (45) from the 3-4 accumulator piston (44). 13. Inspect the 3-4 accumulator piston for the following defects: * Porosity * Cracks * Scoring * Nicks and scratches Installation Procedure 1. Install a new 3-4 accumulator piston seal (45) to the 3-4 accumulator piston (44). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 6846 2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J 36850 . 3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case. Ensure that the 3-4 accumulator piston legs face away from the transmission case. 4. Install the J 25025-B (2, 3) to the transmission case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 6847 5. Place the checkball (1) on the spacer plate in the location shown. 6. Place the 3-4 accumulator spring (2) on the spacer plate. 7. Install the J-25025-5 - guide pins into the case. Note: Do not reuse the bonded spacer plate (48). Replace with a NEW bonded spacer plate. 8. Place the bonded spacer plate on the case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 6848 9. Install the spacer plate support plate (53 or 113). 10. Install the spacer plate bolts (77). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 11. Install the accumulator bolt (115), model dependent and tighten the accumulator bolt to 11 Nm (97 lb in). 12. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. 13. Assemble the 1-2 accumulator. Refer to 1-2 Accumulator Assemble (See: Service and Repair/Overhaul/4L60-E/4L65-E/4L70-E - Automatic Transmission/77. 1-2 Accumulator Assemble). 14. Install the 1-2 accumulator. Refer to 1-2 Accumulator Installation (See: Service and Repair/Overhaul/4L60-E/4L65-E/4L70-E - Automatic Transmission/78. 1-2 Accumulator Installation). 15. Remove the J 25025-B from the transmission case. 16. Install the control valve body. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair/4L60-E/4L65-E/4L70-E Automatic Transmission). 17. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 18. Lower the vehicle. 19. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 6849 20. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM) (See: Description and Operation/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Adaptive Functions (TCM)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair Band Apply Servo: Service and Repair 2-4 Servo Special Tools J 29714-A Servo Cover Depressor Removal Procedure 1. Remove the catalytic converter pipe. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair). 2. Remove the heat shield bolts. 3. Remove the heat shield. 4. Support the transmission. 5. Remove the transmission crossmember. Refer to Transmission Support Crossmember Replacement (2WD 1500/2500) (See: Body and Frame/Frame/Cross-Member/Service and Repair)Transmission Support Crossmember Replacement (4WD 1500/2500) (See: Body and Frame/Frame/Cross-Member/Service and Repair)Transmission Support Crossmember Replacement (2WD 2500 HD/3500) (See: Body and Frame/Frame/Cross-Member/Service and Repair)Transmission Support Crossmember Replacement (4WD 2500 HD/3500) (See: Body and Frame/Frame/Cross-Member/Service and Repair). 6. Lower the transmission with a suitable jack. 7. Remove the oil pan bolt below the servo. 8. Install the J 29714-A . 9. Tighten the bolt on J 29714-A in order to compress the servo cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Page 6853 10. Remove the servo cover ring. 11. Remove the J 29714-A . 12. Remove the servo cover and O-ring seal. If the cover is hung up on the seal, use a pick (2) in order to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover. 13. Remove the 2-4 servo. 14. Inspect the 4th apply piston, 2-4 servo converter, 2nd apply piston, and the servo piston inner housing for the following defects: * Cracks * Scoring * Burrs and nicks Installation Procedure 1. Install NEW seals onto the servo pistons and the servo cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Page 6854 2. Install the 2-4 servo. 3. Install the J 29714-A . 4. Tighten the bolt on J 29714-A in order to compress the servo cover. 5. Install the servo cover ring. 6. Remove the J 29714-A . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the oil pan bolt. Tighten the bolt to 11 Nm (97 lb in). 8. Raise the transmission. 9. Install the transmission crossmember. Refer to Transmission Support Crossmember Replacement (2WD 1500/2500) (See: Body and Frame/Frame/Cross-Member/Service and Repair)Transmission Support Crossmember Replacement (4WD 1500/2500) (See: Body and Frame/Frame/Cross-Member/Service and Repair)Transmission Support Crossmember Replacement (2WD 2500 HD/3500) (See: Body and Frame/Frame/Cross-Member/Service and Repair)Transmission Support Crossmember Replacement (4WD 2500 HD/3500) (See: Body and Frame/Frame/Cross-Member/Service and Repair). 10. Remove the transmission jack. 11. Install the heat shield and bolts. Tighten the bolts to 17 Nm (13 lb ft). 12. Install the catalytic converter pipe. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Engine, Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Page 6855 Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair). 13. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 14. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM) (See: Description and Operation/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Adaptive Functions (TCM)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6864 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6865 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6866 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6872 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6873 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6874 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6875 Control Module: Locations Harness Routing Views Engine Chassis Harness Routing - Top Front (Diesel) 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6876 Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6877 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6878 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6879 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6880 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair Extension Housing: Service and Repair Case Extension Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 5. Remove the transmission mount. Refer to Transmission Mount Replacement (2WD) (See: Transmission Mount/Service and Repair/4L60-E/4L65-E/4L70-E - Automatic Transmission)Transmission Mount Replacement (4WD) (See: Transmission Mount/Service and Repair/4L60-E/4L65-E/4L70-E - Automatic Transmission). 6. Remove the case extension bolts (1). 7. Remove the case extension (2). 8. Remove and discard the case extension O-ring seal (3). Installation Procedure 1. Install a new case extension O-ring seal (3). 2. Install the case extension (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the case extension bolts (1). Tighten the bolts (1) to 45 Nm (33 lb ft). 4. Install the transmission mount. Refer to Transmission Mount Replacement (2WD) (See: Transmission Mount/Service and Repair/4L60-E/4L65-E/4L70-E - Automatic Transmission)Transmission Mount Replacement (4WD) (See: Transmission Mount/Service and Repair/4L60-E/4L65-E/4L70-E - Automatic Transmission). 5. Install the propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E Automatic Transmission/Transmission Fluid Level Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > Page 6884 and Condition Check). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information > Page 6889 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications AUTOMATIC TRANSMISSION FLUID CAPACITY 4L60-E / 4L65-E / 4L70-E Automatic Transmission Pan Removal ...................................................... ................................................................................................................................... 4.7 liters (5.0 quarts) Overhaul .................................................................................................................................. ......................................................... 10.6 liters (11.0 quarts) 300 mm Torque Converter Approximate Dry Fill ............................................................................................................................ ................................................................ 11.50 liters (12.1 quarts) 6L80 AUTOMATIC TRANSMISSION Pan Removal ........................................................................... .............................................................................................................. 5.7 liters (6.0 quarts) Overhaul .............................................................................................................................................. ............................................... 9.9 liters (10.5 quarts) Complete Trans System .................................. .................................................................................................................................. 11.7 liters (12.4 quarts) 6L90 AUTOMATIC TRANSMISSION Pan Removal ........................................................................... .............................................................................................................. 6.0 liters (6.3 quarts) Overhaul .............................................................................................................................................. ............................................... 9.9 liters (10.5 quarts) Complete Trans System .................................. .................................................................................................................................. 11.7 liters (12.4 quarts) 2ML70 AUTOMATIC TRANSMISSION Drain Plug Only ..................................................................... ........................................................................................................... 9.93 liters (10.5 quarts) Drop Pan and Filter ...................................................................................................................................... ................................... 10.88 liters (11.5 quarts) Dry Transmission (Empty) .............................................................................................................................................................. 12.30 liters (13.0 quarts) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 6892 Fluid - A/T: Fluid Type Specifications Automatic Transmission DEXRON-VI Automatic Transmission Fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 6893 Fluid - A/T: Service and Repair Automatic Transmission Fluid and Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair). 6. Remove the oil pan bolts from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 9. Remove the remaining oil pan bolts. 10. Remove the oil pan and the gasket. 11. Grasp firmly while pulling down with a twisting motion in order to remove the filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 6894 12. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: * Clutch material * Bronze slivers indicating bushing wear * Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. 4. Install the oil pan and NEW gasket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 6895 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the oil pan bolts. Tighten the bolts alternately and evenly to 11 Nm (97 lb in). 6. Install the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) ( See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair). 7. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 Nm (18 lb ft). 8. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E Automatic Transmission/Transmission Fluid Level and Condition Check) and Fluid Capacity Specifications (See: Specifications). 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Filter - A/T: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Fluid and Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair). 6. Remove the oil pan bolts from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 9. Remove the remaining oil pan bolts. 10. Remove the oil pan and the gasket. 11. Grasp firmly while pulling down with a twisting motion in order to remove the filter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6900 12. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: * Clutch material * Bronze slivers indicating bushing wear * Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. 4. Install the oil pan and NEW gasket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6901 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the oil pan bolts. Tighten the bolts alternately and evenly to 11 Nm (97 lb in). 6. Install the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) ( See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair). 7. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 Nm (18 lb ft). 8. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E Automatic Transmission/Transmission Fluid Level and Condition Check) and Fluid Capacity Specifications (See: Fluid - A/T/Specifications). 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6902 Fluid Filter - A/T: Service and Repair Allison - Automatic Transmission Automatic Transmission Fluid and Filter Replacement Removal Procedure Note: DO NOT drain the fluid if only the transmission external oil filter is being replaced. 1. Remove the drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. 2. Inspect the drained fluid. Refer to Transmission Fluid Level and Condition Check (). Note: Use a standard strap-type filter wrench to remove the transmission external oil filter. 3. Remove the filter (4) by rotating in the counterclockwise direction. 4. Remove the magnet (2) from the filter adapter (1) in the converter housing or from the top of the transmission external oil filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Install the magnet (2) onto the filter adapter (1) which is in the converter housing. 2. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 3. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Caution: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 4. Turn the filter ONE FULL TURN ONLY after gasket contact. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the drain plug (6) and drain plug seal (5). Tighten the drain plug to 35 Nm (26 lb ft). 6. Refill Transmission with DEXRON(R)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications (See: Fluid - A/T/Specifications ). Note: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6903 7. Cycle the ignition until Drive or Reverse range is attained. Note: Fluid remains in the external circuits and transmission cavities after draining the transmission. 8. Check the transmission fluid level. Refer to Transmission Fluid Level and Condition Check (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Line/Hose: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Fluid Cooler Hose/Pipe Replacement Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Remove the transmission fluid cooler hose from the Auxiliary oil cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 3. Remove the transmission fluid cooler hose from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the transmission cooling line bracket retaining bolt (2). 6. Remove the cooling lines from the transmission. 7. Remove the oil cooling lines from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6908 1. Install the transmission oil cooler lines to the vehicle. 2. Install the cooler lines to the transmission. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the transmission cooler line bracket bolt (2) and tighten to 22 Nm (16 lb ft). 4. Lower the vehicle. 5. Install the transmission fluid cooler hose to the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 6. Install the transmission fluid cooler hose to the Auxiliary oil cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 7. Install the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Transmission Fluid Cooler Hose/Pipe Connector Replacement (Radiator) Transmission Fluid Cooler Hose/Pipe Connector Replacement (Radiator) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6909 Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Special Tools * DT-28585 - Universal Snap Ring Remover for the 5/8 inch Line * DT-41623-B - 3/8 inch Line Quick Release Tool 3/8 inch Line Quick Release Tool Removal Procedure 1. Remove the plastic caps from the quick connect fittings by pulling the caps back along the pipe before installation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6910 2. Install the DT-41623-B - 3/8 inch Line Quick Release Tool onto the transmission oil cooler (TOC) pipe, or use theDT-28585 - Universal Snap Ring Remover for the 5/8 inch Line 3. Slide the DT-41623-B - 3/8 inch Line Quick Release Tool toward the TOC pipe fitting, or use the DT-28585 - Universal Snap Ring Remover for the 5/8 inch Line Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6911 Note: Rotate the DT-41623-B - 3/8 inch Line Quick Release Tool to engage the TOC pipe fitting's retainer slots. The DT-41623-B - 3/8 inch Line Quick Release Tool should be nearly flush with the fitting. 4. Connect the DT-41623-B - 3/8 inch Line Quick Release Tool onto the TOC pipe fitting. 5. Rotate the DT-41623-B - 3/8 inch Line Quick Release Tool or use the DT-28585 - Universal Snap Ring Remover for the 5/8 inch Line until the retainer clip (1) rises above the fitting retainer seat. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6912 6. Pull back on the TOC pipe to disengage the pipe from the TOC pipe fitting. 7. Remove the DT-41623-B - 3/8 inch Line Quick Release Tool or the DT-28585 - Universal Snap Ring Remover for the 5/8 inch Line from the TOC pipe. Installation Procedure Note: Discard the TOC retaining clip and install a new retaining clip. 1. Install the TOC pipe into the TOC pipe fitting. A distinct snap should be heard or felt when assembling the TOC pipe to the fitting. 2. To ensure the cooler line is properly installed, give the cooler pipe a gentle pull. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6913 Fluid Line/Hose: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Removal Procedure Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. 1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure Important: * Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. * Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. * Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 1. Install a new retaining ring into the quick connect fitting using the following procedure: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6914 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6915 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. Important: Do not manually depress the retaining clip when installing the plastic cap. 10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6916 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. 14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E Automatic Transmission/Transmission Fluid Level and Condition Check). Transmission Fluid Cooler Hose/Pipe Connector Replacement (Radiator) Transmission Fluid Cooler Hose/Pipe Connector Replacement (Radiator) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6917 Transmission Fluid Cooler Hose/Pipe Replacement Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6918 2. Remove the transmission fluid cooler hose from the Auxiliary oil cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 3. Remove the transmission fluid cooler hose from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the transmission cooling line bracket retaining bolt (2). 6. Remove the cooling lines from the transmission. 7. Remove the oil cooling lines from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6919 1. Install the transmission oil cooler lines to the vehicle. 2. Install the cooler lines to the transmission. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the transmission cooler line bracket bolt (2) and tighten to 22 Nm (16 lb ft). 4. Lower the vehicle. 5. Install the transmission fluid cooler hose to the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 6. Install the transmission fluid cooler hose to the Auxiliary oil cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 7. Install the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pan: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Oil Pan Screws .................................................................................................................................... ...................................................... 16 Nm (11.8 lb ft) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6924 Fluid Pan: Specifications 6L45/6L50/6L80/6L90 - Automatic Transmission Fluid Pan Bolts .................................................................................................................................... .......................................................... 9 Nm (80 lb in) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair Parking Pawl: Service and Repair Manual Shift Detent Lever and Park Pawl Actuator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 6935 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6939 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6949 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6950 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6951 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6957 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6958 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6959 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6960 Control Module: Locations Harness Routing Views Engine Chassis Harness Routing - Top Front (Diesel) 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6961 Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6962 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6963 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6964 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6965 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Seals and Gaskets: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement Special Tools * J 43911 Selector Shaft Seal Remover * J 43909 Selector Shaft Seal Installer Removal Procedure 1. Disconnect the range selector lever cable and lever from the manual shaft. 2. Ensure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 3. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to ensure that the removal tool is firmly attached to the seal shell. 4. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the bore until it is seated at the bottom of the bore. 4. Connect the range selector lever cable and lever to the manual shaft. 5. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E Automatic Transmission/Transmission Fluid Level and Condition Check). Propeller Shaft Front Slip Yoke Oil Seal Replacement Propeller Shaft Front Slip Yoke Oil Seal Replacement Tools Required * J 21426 Extension Housing Seal Installer * J 36850 Transjel Lubricant Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6970 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 4. Remove the case extension housing rear oil seal. Use a flat bladed tool and carefully pry the seal from the housing. 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Refer to Case Extension Assembly Replacement (See: Extension Housing/Service and Repair). Installation Procedure 1. Lubricate the inside diameter of the new seal with J 36850 . 2. Use the J 21426 with a soft faced mallet to install the seal. 3. Install the seal to the extension housing. 4. Install the propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E Automatic Transmission/Transmission Fluid Level and Condition Check). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6971 Seals and Gaskets: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Transmission Output Shaft Seal Replacement (Four Wheel Drive) Transmission Output Shaft Seal Replacement (Four Wheel Drive) Propeller Shaft Front Slip Yoke Oil Seal Replacement (Two Wheel Drive) Propeller Shaft Front Slip Yoke Oil Seal Replacement (Two Wheel Drive) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6972 Manual Shift Shaft and Seal Replacement Manual Shift Shaft and Seal Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 6973 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6986 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6987 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6988 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6994 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6995 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6996 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 6997 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Parking Lock and Manual Shift Detent Lever with Shaft Position Switch Assembly 78 - Steel Cup Plug 79 - Parking Brake Pawl Shaft 80 - Parking Pawl Return Spring 81 - Parking Brake Pawl 82 - Manual Shaft Seal 84 - Manual Shaft - Model Dependent 85 - Parking Lock Actuator Assembly 86 - Parking Lock Bracket 87 - Parking Lock Bracket Bolt 88 - Manual Shift Detent Lever with Shaft Position Switch Assembly 89 - Manual Valve Link 92 - Manual Shift Detent Lever Hub Pin Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 7002 Transmission Position Switch/Sensor: Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 7003 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 7006 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 7007 Transmission Position Switch/Sensor: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Fluid Line/Hose/Service and Repair). 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 Nm (9 lb ft). 3. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Fluid Line/Hose/Service and Repair). 4. Install the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E Automatic Transmission > Page 7008 Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Speed Sensor: Component Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 7013 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Oil Pump Assembly 200 - Pump Body 201 - Oil Seal Ring - Slide to Wear Plate 202 - O-Ring Seal - Slide Seal Back-Up 203 - Pump Slide 204 - Pivot Pin Spring 205 - Pivot Slide Pin 208 - Pump Slide Seal Support 209 Pump Slide Seal 210 - Pump Vane Ring 210 - Pump Vane Ring 211 - Rotor Guide 212 - Oil Pump Rotor 213 - Pump Vane 214 - Stator Shaft 215 - Pump Cover 216 - Pressure Regulator Valve Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 7014 217 - Pressure Regulator Valve Spring 218 - Pressure Regulator Isolator Spring 219 - Reverse Boost Valve 220 - Reverse Boost Valve Sleeve 221 - Oil Pump Reverse Boost Valve Retaining Ring 222 - Oil Pump Converter Clutch Valve Retaining Ring 223 - Stop Valve 224 - Converter Clutch Valve - Model Dependent 227 - Pressure Relief Bolt Rivet 228 - Pressure Relief Ball 229 Pressure Relief Spring 230 - Oil Seal Ring - Stator Shaft 231 - Oil Pump Cover Screen Seal 232 Oil Pump Cover Screen 233 - Bolt M8 X 1.25 X 40 - Cover to Body 234 - Stator Shaft Bushing Front 235 - Oil Pump Cover Plug - FWD Clutch Feed 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 237 - Check Valve Retainer and Ball Assembly 237 - Check Valve Retainer and Ball Assembly 238 - Converter Clutch Signal Orifice - Cup Plug 240 - Cup Orifice Plug 241 Stator Shaft Bushing - Rear 242 - Pump Body Bushing 243 - Oil Seal Assembly 244 - Fluid Seal Retainer 245 - A/T Fluid Pump Slide Outer Spring 246 - Converter Clutch Valve Spring 247 - A/T ISS Attaching Bolt - Model Dependent 249 - O-ring 250 - A/T Input Speed Sensor (ISS) Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 7015 Transmission Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 7016 Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 7017 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 7018 Transmission Speed Sensor: Service and Repair Input and Output Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 7022 Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 7027 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7032 Shift Solenoid: Specifications 6L45/6L50/6L80/6L90 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 7033 Shift Solenoid: Locations Disassembled Views Control Valve Body Assembly (1 of 2) 350 - Control Valve Body Assembly 353 - Forward Accumulator Oil Seal 354 - Forward Accumulator Piston 355 - Forward Accumulator Pin 356 - Forward Accumulator Spring 357 Forward Abuse Valve 358 - Forward Abuse Valve Spring 359 - Bore Plug 360 - Coiled Spring Pin 360 - Coiled Spring Pin 361 - Low Overrun Valve 362 - Low Overrun Valve Spring 363 - Forward Accumulator Cover 364 - Forward Accumulator Cover Bolt 364a - Pressure Control Solenoid Retainer Bolt 365 - 1-2 Shift Valve Spring - Model Dependent 366 - 1-2 Shift Valve - Model Dependent 367a - 1-2 Shift Solenoid Valve 367b - 2-3 Shift Solenoid Valve 368 - 2-3 Shift Valve 369 - 2-3 Shuttle Valve 370 - 1-2 Accumulator Valve Spring 371 - 1-2 Accumulator Valve 372 - 1-2 Accumulator Valve Sleeve 374 - Actuator Feed Limit Valve 375 - Actuator Feed Limit Valve Spring 376 - Bore Plug 377 - Pressure Control Solenoid Valve Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 7034 378 - Pressure Control Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7041 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7042 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7043 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7044 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7045 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7046 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7047 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7048 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7049 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7050 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7051 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7052 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7053 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7054 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7055 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7056 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7057 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7058 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7059 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7060 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7061 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7062 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7063 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7064 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7065 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7066 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7067 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7068 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7069 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7070 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7071 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7072 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7073 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7074 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7075 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7076 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7077 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7078 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7079 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7080 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7081 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7082 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7083 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7084 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7085 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7086 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7087 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7088 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7089 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7090 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7091 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7092 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7093 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7094 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7095 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7096 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7097 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7098 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7099 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7100 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7101 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7102 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7103 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7104 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7105 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7106 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7107 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7108 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7109 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7110 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7111 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7112 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7113 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7114 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7115 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7116 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7117 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7118 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7119 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7120 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7121 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7122 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7123 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7124 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7125 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7126 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7127 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7128 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7129 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7130 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7131 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7132 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7133 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7134 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7135 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7136 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7137 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7138 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7139 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7140 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7141 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7142 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7143 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7144 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7145 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7146 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7147 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7148 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7149 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7150 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7151 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7152 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7153 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7154 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7155 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7156 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7157 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7158 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7159 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7160 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7161 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7162 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7163 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7164 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7165 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7166 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7167 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7168 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7169 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7170 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7171 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7172 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7173 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7174 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7175 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7176 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7177 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7178 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7179 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7180 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7181 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7182 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7183 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7184 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7185 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7186 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7187 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7188 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7189 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7190 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7191 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7192 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7193 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7194 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7195 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7196 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7197 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7198 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7199 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7200 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7201 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7202 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7203 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7204 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7205 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7206 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7207 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7208 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7209 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7210 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7211 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7212 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7213 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7214 Shift Solenoid: Connector Views Component Connector End Views Control Solenoid Valve Assembly X1 (MYC, MYD or M99) Control Solenoid Valve Assembly X2 (MYC, MYD or M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7215 Control Solenoid Valve Assembly X3 (MYC, MYD or M99) 1-2 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7216 2-3 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7217 Shift Solenoid (SS) Valve 1 (MW7) Shift Solenoid (SS) Valve 2 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7218 Shift Solenoid (SS) Valve 3 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Note: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 3. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7221 4. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). 5. Remove the pressure control solenoid (377). Note the orientation upon removal. 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. Installation Procedure Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 1. Install the 1-2 and 2-3 shift solenoids. 2. Install the 1-2 and 2-3 shift solenoid retainers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7222 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 lb in) 4. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 5. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 6. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 7. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7223 Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 8. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM) (See: Description and Operation/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Adaptive Functions (TCM)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7224 Shift Solenoid: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7225 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Diagrams Shifter A/T: Diagrams Component Connector End Views Automatic Transmission Shift Lever (M30, MYC, MYD, M99 or MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Diagrams > Page 7229 Shifter A/T: Service and Repair Shift Lever Replacement Removal Procedure 1. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 2. Roll back the shift lever seal on the shift lever until the shift lever bolt is exposed. 3. Disconnect any electrical connectors as needed. 4. Remove the shift lever bolt (2). 5. Remove the shift lever (1). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Diagrams > Page 7230 1. Install the shift lever (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the shift lever bolt (2) and tighten to 20 Nm (15 lb ft). 3. Connect all electrical connectors. 4. Position the shift lever seal. 5. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Shift Cable: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7240 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7241 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7242 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Shift Cable: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7248 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7249 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7250 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Cable: Adjustments 4L60-E/4L65-E/4L70-E - Automatic Transmission Range Selector Lever Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7253 Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 7. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. Refer to cable re-adjustment below. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Refer to cable re-adjustment below. Cable Re-Adjustment Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7254 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat-bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 6. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7255 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7256 Shift Cable: Adjustments 6L45/6L50/6L80/6L90 - Automatic Transaxle Range Selector Lever Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7257 Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 7. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. Refer to cable re-adjustment below. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Refer to cable re-adjustment below. Cable Re-Adjustment Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7258 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat-bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 6. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7259 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Cable: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Range Selector Lever Cable Replacement Range Selector Lever Cable Replacement Removal Procedure Warning The automatic transaxle range selector cable is made out of two cable sections. After initial connection never separate the two metal couplings from one another. Integrity of the connection of the two metal couplings will be lost if separation of the two metal couplings occurs. When servicing the transaxle remove the cable at the automatic transaxle range selector lever and at the automatic transaxle range selector cable bracket. If either section of the cable needs to be replaced, replace both of the cable sections. Loss of connection integrity of the two metal couplings can cause loss of transaxle shift control which could result in personal injury. 1. Position the steering column shift lever to the park position. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the clips on the cable from the floor panel reinforcement. 4. Ensure the transmission manual shaft is positioned in mechanical park. 5. Remove the retainer that secures the cable to the bracket. 6. Remove the cable clip on the transfer case, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7262 7. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). 8. Depress the tangs and remove the cable from the bracket. 9. Lower the vehicle. 10. Ensure that the steering column shift lever is still in the park position. 11. Remove the drivers seat. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Replacement - Bucket). 12. Pull back the carpet and insulation around the driver's area. 13. Remove the instrument panel knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 14. Remove the retainer securing the cable to the steering column. 15. Remove the cable end from the steering column ball stud. 16. Depress the tangs and remove the cable from the steering column bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7263 Note: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. 17. Remove the range selector cable from the support. 18. Remove the cable grommet from the floor panel. 19. Remove the cable from the vehicle. Installation Procedure 1. Install the cable to the vehicle. 2. Install the cable grommet to the floor panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7264 Note: Avoid unnecessary twisting/bending of the range selector cable when installing the cable to the support. 3. Install the range selector cable to the support. 4. Ensure that the transmission manual shaft lever is in the mechanical park position. 5. Install the cable to the steering column bracket. 6. Ensure the tangs fully seat (snap) into the steering column bracket. 7. Install the cable end to the steering column ball stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7265 8. Install the retainer securing the cable to the steering column. 9. Position the carpet and insulation around the driver's area. 10. Install the drivers seat. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Replacement - Bucket). 11. Install the instrument panel knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 12. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 13. Align and install the cable to the bracket. 14. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). 15. Install the cable clip on the transfer case, if equipped. 16. Install the retainer that secures the cable to the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7266 17. Install the clips on the cable to the floor panel reinforcement. 18. Lower the vehicle. 19. Test the transmission for proper shift operation. 20. If all of the gear positions cannot be achieved, adjust the cable. Refer to Range Selector Lever Cable Adjustment (See: Adjustments). Range Selector Lever Cable Bracket Replacement Range Selector Lever Cable Bracket Replacement Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Remove the retainer that secures the cable to the bracket. 5. Depress the tangs and remove the cable from the bracket. 6. Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission. 7. Remove the transmission range selector cable bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7267 1. Install the transmission range selector cable bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission range selector cable bracket bolts (1) and tighten to 25 Nm (18 lb ft). 3. Align and install the cable to the bracket. 4. Install the retainer that secures the cable to the bracket. 5. Lower the vehicle. 6. Check the vehicle for proper operation. If cable adjustment is necessary, refer to Range Selector Lever Cable Adjustment (See: Adjustments). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7268 Shift Cable: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transaxle Range Selector Lever Cable Replacement Range Selector Lever Cable Replacement Removal Procedure Warning The automatic transaxle range selector cable is made out of two cable sections. After initial connection never separate the two metal couplings from one another. Integrity of the connection of the two metal couplings will be lost if separation of the two metal couplings occurs. When servicing the transaxle remove the cable at the automatic transaxle range selector lever and at the automatic transaxle range selector cable bracket. If either section of the cable needs to be replaced, replace both of the cable sections. Loss of connection integrity of the two metal couplings can cause loss of transaxle shift control which could result in personal injury. 1. Position the steering column shift lever to the park position. 2. Remove the instrument panel knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Remove the driver seat. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Replacement - Bucket). 4. Pull back the carpet and insulation around the driver area. 5. Remove the retainer securing the cable to the steering column. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7269 6. Remove the cable end from the steering column ball stud. 7. Depress the tangs and remove the cable from the steering column bracket. Note: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. 8. Remove the range selector cable from the support. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7270 9. Remove the cable grommet from the floor panel. 10. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 11. Remove the clips on the cable from the floor panel reinforcement. 12. Ensure the transmission manual shaft is positioned in mechanical park. 13. Remove the cable clip on the transfer case, if equipped. 14. Remove the range selector cable (2) from the transmission range selector lever ball stud. 15. Remove the retainer (1) that secures the cable to the bracket. 16. Depress the tangs and remove the cable from the bracket. 17. Remove the transmission range selector cable from the vehicle. Installation Procedure 1. Install the transmission range selector cable to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7271 2. Ensure that the transmission manual shaft lever is in the mechanical park position. 3. Align and install the range selector cable (2) to the bracket. 4. Install the retainer (1) that secures the cable to the bracket. 5. Install the range selector cable end to the transmission range selector lever ball stud. 6. Install the cable clip on the transfer case, if equipped. 7. Install the clips on the cable to the floor panel reinforcement. 8. Lower the vehicle and ensure that the steering column shift lever is still in the park position. 9. Install the cable grommet to the floor panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7272 Note: Avoid unnecessary twisting/bending of the range selector cable when installing the cable to the support. 10. Install the range selector cable to the support. 11. Install the cable to the steering column bracket. 12. Ensure the tangs fully engage into the steering column bracket. 13. Install the cable end to the steering column ball stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7273 14. Install the retainer securing the cable to the steering column. 15. Position the carpet and insulation around the driver area. 16. Install the driver seat. Refer to Front Seat Replacement Bucket (See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Replacement - Bucket). 17. Install the instrument panel knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 18. Test the transmission for proper shift operation. 19. If all of the gear positions cannot be achieved, adjust the cable. Refer to Range Selector Lever Cable Adjustment (See: Adjustments). Range Selector Lever Cable Bracket Replacement Range Selector Lever Cable Bracket Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7274 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Service and Repair Torque Converter Check Valve: Service and Repair Torque Converter Clutch Valve and Spring Replacement Removal Procedure 1. Remove the transmission filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 2. Disconnect the torque converter clutch (TCC) pulse width modulation (PWM) solenoid electrical connector. 3. Remove the TCC PWM solenoid retainer. 4. Remove the TCC PWM solenoid in order to access the TCC control solenoid bolts. 5. Disconnect the TCC control solenoid connector. 6. Remove the TCC control solenoid retaining bolts. 7. Remove the TCC control solenoid. Warning Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 8. Remove the TCC valve retainer ring (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Service and Repair > Page 7278 9. Remove the following parts: * The valve bore plug * The TCC valve * The TCC valve spring(s) Installation Procedure Note: * Clean and inspect the TCC solenoid O-ring for cuts, nicks, and damage. Replace if necessary. * Inspect the TCC bore for sediment and debris. Flush the bore if necessary. * Clean and inspect the TCC valve for binding, scoring, and damage. * Inspect the TCC spring for cracks and deformed or broken coils. 1. Install the following parts: * The TCC valve spring * The TCC valve * The valve bore plug 2. Install the TCC valve retainer ring (1). 3. Install the TCC control solenoid. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the TCC control solenoid retaining bolts and tighten to 8-14 Nm (71-124 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Service and Repair > Page 7279 5. Connect the TCC control solenoid connector. 6. Install the TCC PWM solenoid. 7. Install the TCC PWM solenoid retainer. 8. Connect the TCC PWM Solenoid electrical connector. 9. Install the transmission filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7284 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7285 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7286 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7287 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7288 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7289 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7290 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7291 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7292 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7293 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7294 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7295 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7296 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7297 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7298 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7299 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7300 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7301 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7302 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7303 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7304 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7305 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7306 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7307 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7308 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7309 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7310 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7311 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7312 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7313 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7314 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7315 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7316 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7317 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7318 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7319 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7320 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7321 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7322 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7323 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7324 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7325 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7326 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7327 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7328 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7329 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7330 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7331 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7332 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7333 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7334 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7335 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7336 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7337 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7338 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7339 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7340 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7341 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7342 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7343 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7344 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7345 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7346 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7347 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7348 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7349 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7350 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7351 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7352 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7353 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7354 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7355 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7356 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7357 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7358 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7359 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7360 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7361 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7362 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7363 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7364 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7365 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7366 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7367 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7368 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7369 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7370 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7371 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7372 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7373 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7374 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7375 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7376 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7377 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7378 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7379 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7380 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7381 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7382 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7383 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7384 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7385 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7386 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7387 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7388 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7389 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7390 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7391 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7392 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7393 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7394 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7395 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7396 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7397 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7398 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7399 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7400 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7401 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7402 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7403 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7404 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7405 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7406 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7407 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7408 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7409 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7410 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7411 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7412 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7413 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7414 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7415 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7416 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7417 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7418 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7419 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7420 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7421 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7422 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7423 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7424 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7425 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7426 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7427 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7428 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7429 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7430 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7431 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7432 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7433 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7434 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7435 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7436 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7437 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7438 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7439 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7440 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7441 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7442 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7443 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7444 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7445 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7446 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7447 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7448 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7449 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7450 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7451 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7452 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7453 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7454 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7455 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7456 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7457 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7458 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7459 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7460 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7461 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7462 Torque Converter Clutch (TCC) Solenoid Valve (M30) Wiring Diagram Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 7463 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and Wiring Harness Special Tools J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and the filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 3. Disconnect the transmission harness 20 way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up. Do not pry the connector. Note: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 5. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 7464 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the TCC solenoid bolts (68). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 7465 9. Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so the wiring harness hangs down. 10. Remove the solenoid retainer bolt (36A) and the solenoid retainer (378). 11. Remove the pressure control solenoid (377). Note the orientation upon removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 7466 12. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. 13. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the 4 tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 14. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly (66) from the transmission case. 15. Inspect the TCC solenoid and wiring harness assembly for the following defects: * Damage * Cracked connectors * Exposed wires * Loose pins Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 7467 1. Install the wiring harness and TCC solenoid assembly (66) with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. 1. Tighten the control valve body retaining bolts to 11 Nm (97 lb in). 2. Tighten the TCC solenoid retaining bolts to 11 Nm (97 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 7468 Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 4. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. The solenoid retainer bolt (364) Tighten the solenoid retainer bolt to 11 Nm (97 lb in) 5. Install the TCC PWM solenoid to the control valve body. 6. Install the TCC PWM solenoid retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 7469 7. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 8. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Accumulator/Service and Repair). 9. Connect the transmission harness 20 way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 10. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 11. Lower the vehicle. 12. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 13. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM) (See: Description and Operation/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Adaptive Functions (TCM)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Service and Repair Torque Converter Cover: Service and Repair Torque Converter Cover Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7477 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7478 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7479 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7480 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 7481 Transmission Cooler: Service and Repair Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Fluid Line/Hose/Service and Repair). 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 Nm (9 lb ft). 3. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Fluid Line/Hose/Service and Repair). 4. Install the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7490 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7491 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7492 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7498 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7499 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7500 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 7501 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Testing and Inspection > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Mount: Testing and Inspection 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Mount Inspection Caution: In order to avoid oil pan damage and possible engine failure, insert a block of wood that spans the width of the oil pan bottom between the oil pan and the jack support. 1. Raise the transmission/transaxle in order to remove the weight from the transmission/transaxle mount and create slight tension in the rubber. 2. Observe the transmission/transaxle mount while raising the transmission/transaxle. Replace the transmission/transaxle mount if the transmission/transaxle mount exhibits any of the following conditions: Note: Black paint on the rubber will crack with time, this does no constitute a failure. * The hard rubber surface is covered with heat check cracks. * The rubber is separated from the metal plate of the transmission/transaxle mount. * The rubber is split through the center of the transmission/transaxle mount. 3. If there is movement between the metal plate of the transmission/transaxle mount and its attaching points, lower the transmission/transaxle on the transmission/transaxle mount. Tighten the bolts or nuts attaching the transmission/transaxle mount to the frame or transmission/transaxle mount bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Testing and Inspection > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7506 Transmission Mount: Testing and Inspection 6L45/6L50/6L80/6L90 - Automatic Transmission Transmission Mount Inspection Caution: In order to avoid oil pan damage and possible engine failure, insert a block of wood that spans the width of the oil pan bottom between the oil pan and the jack support. 1. Raise the transmission/transaxle in order to remove the weight from the transmission/transaxle mount and create slight tension in the rubber. 2. Observe the transmission/transaxle mount while raising the transmission/transaxle. Replace the transmission/transaxle mount if the transmission/transaxle mount exhibits any of the following conditions: Note: Black paint on the rubber will crack with time, this does no constitute a failure. * The hard rubber surface is covered with heat check cracks. * The rubber is separated from the metal plate of the transmission/transaxle mount. * The rubber is split through the center of the transmission/transaxle mount. 3. If there is movement between the metal plate of the transmission/transaxle mount and its attaching points, lower the transmission/transaxle on the transmission/transaxle mount. Tighten the bolts or nuts attaching the transmission/transaxle mount to the frame or transmission/transaxle mount bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Mount: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Mount Replacement (4WD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7509 Transmission Mount: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Transmission Mount Replacement (4WD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Parking Lock and Manual Shift Detent Lever with Shaft Position Switch Assembly 78 - Steel Cup Plug 79 - Parking Brake Pawl Shaft 80 - Parking Pawl Return Spring 81 - Parking Brake Pawl 82 - Manual Shaft Seal 84 - Manual Shaft - Model Dependent 85 - Parking Lock Actuator Assembly 86 - Parking Lock Bracket 87 - Parking Lock Bracket Bolt 88 - Manual Shift Detent Lever with Shaft Position Switch Assembly 89 - Manual Valve Link 92 - Manual Shift Detent Lever Hub Pin Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7514 Transmission Position Switch/Sensor: Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 7515 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7518 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7519 Transmission Position Switch/Sensor: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Fluid Line/Hose/Service and Repair). 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 Nm (9 lb ft). 3. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Fluid Line/Hose/Service and Repair). 4. Install the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7520 Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Speed Sensor: Component Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 7525 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Oil Pump Assembly 200 - Pump Body 201 - Oil Seal Ring - Slide to Wear Plate 202 - O-Ring Seal - Slide Seal Back-Up 203 - Pump Slide 204 - Pivot Pin Spring 205 - Pivot Slide Pin 208 - Pump Slide Seal Support 209 Pump Slide Seal 210 - Pump Vane Ring 210 - Pump Vane Ring 211 - Rotor Guide 212 - Oil Pump Rotor 213 - Pump Vane 214 - Stator Shaft 215 - Pump Cover 216 - Pressure Regulator Valve Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 7526 217 - Pressure Regulator Valve Spring 218 - Pressure Regulator Isolator Spring 219 - Reverse Boost Valve 220 - Reverse Boost Valve Sleeve 221 - Oil Pump Reverse Boost Valve Retaining Ring 222 - Oil Pump Converter Clutch Valve Retaining Ring 223 - Stop Valve 224 - Converter Clutch Valve - Model Dependent 227 - Pressure Relief Bolt Rivet 228 - Pressure Relief Ball 229 Pressure Relief Spring 230 - Oil Seal Ring - Stator Shaft 231 - Oil Pump Cover Screen Seal 232 Oil Pump Cover Screen 233 - Bolt M8 X 1.25 X 40 - Cover to Body 234 - Stator Shaft Bushing Front 235 - Oil Pump Cover Plug - FWD Clutch Feed 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 237 - Check Valve Retainer and Ball Assembly 237 - Check Valve Retainer and Ball Assembly 238 - Converter Clutch Signal Orifice - Cup Plug 240 - Cup Orifice Plug 241 Stator Shaft Bushing - Rear 242 - Pump Body Bushing 243 - Oil Seal Assembly 244 - Fluid Seal Retainer 245 - A/T Fluid Pump Slide Outer Spring 246 - Converter Clutch Valve Spring 247 - A/T ISS Attaching Bolt - Model Dependent 249 - O-ring 250 - A/T Input Speed Sensor (ISS) Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 7527 Transmission Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 7528 Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 7529 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 7530 Transmission Speed Sensor: Service and Repair Input and Output Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 7534 Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - Control Valve/Solenoid Cleaning Information Valve Body: Technical Service Bulletins A/T - Control Valve/Solenoid Cleaning Information INFORMATION Bulletin No.: 07-07-30-006B Date: March 02, 2010 Subject: Information on Control Solenoid Valve and Transmission Control Solenoid Module Assembly Cleaning Procedure for Rear Wheel Drive Six-Speed HYDRA-MATIC(R) Automatic Transmissions when MIL/DTCs Set Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 Equipped with Six Speed HYDRA-MATIC(R) 6L50, 6L80 or 6L90 Automatic Transmission (RPOs MYB, MYC, MYD) Supercede: This bulletin is being updated to add models and model years and to advise technicians that the control solenoid valve assembly cleaning procedure is no longer valid. Please discard Corporate Bulletin Number 07-07-30-006A (Section 07 - Transmission/Transaxle). The control solenoid (w/body and TCM) valve assembly cleaning procedure has been determined to be ineffective. This procedure will be removed from the scan tool and will be no longer available for use. Reference to this procedure will be removed from SI diagnostics and labor operation K9450 will be removed from the Labor Time Guide. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - Control Valve/Solenoid Cleaning Information > Page 7539 Valve Body: Technical Service Bulletins A/T - Valve Body Reconditioning Info. INFORMATION Bulletin No.: 08-07-30-006A Date: October 13, 2009 Subject: HYDRA-MATIC(R) 6L45 (MYA), 6L50 (MYB), 6L80 (MYC) and 6L90 (MYD), Rear Wheel Drive Automatic Transmission Control Valve Body Assembly Reconditioning Models: 2006-2009 Cadillac XLR 2006-2010 Cadillac STS 2007-2009 Cadillac SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2010 Cadillac CTS 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon Denali, Yukon Denali XL 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L45, 6L50, 6L80 or 6L90 HYDRA-MATIC(R) Rear Wheel Drive Automatic Transmission (RPOs MYA, MYB, MYC, MYD) Supercede: This bulletin is being revised to update model years and add 6L45 transmission (RPO MYA). Please discard Corporate Bulletin Number 08-07-30-006 (Section 07 Transmission/Transaxle). The information outlined in this bulletin is designed to provide easy to follow control valve body reconditioning instructions using the new illustrations to simplify reassembly of the 6L45, 6L50, 6L80 and/or 6L90 automatic transmission control valve body assembly. Caution Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Notice After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. Notice Do not reuse cleaning solvents. Previously used solvents may deposit sediment, which may damage the component. Inspection Procedure for Shift Concerns 1. Using the exploded view, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. IF VALVE BODY CLEANING IS NOT REQUIRED, DO NOT DISASSEMBLE THE BORES UNLESS IT IS NECESSARY TO VERIFY MOVEMENT. 2. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. 3. If a valve is restricted and cannot be corrected by cleaning the valve and bore, replace the valve body. Describe the restricted valve on the repair order. Disassembly/Reassembly for Cleaning Debris 1. If a valve is restricted by a metal burr from machining that bore, remove the valve and burr. Inspect the movement in the valve's normal position. If no other debris or restrictions are found, reassemble the valve body and install in the transmission. 2. If the valve body has been contaminated with debris from another transmission component failure, disassemble all bores for complete cleaning of all valve body components. Keeping individual bore parts separated will make reassembly easier. Use the following illustrations for positive identification and location of individual parts. 3. Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - Control Valve/Solenoid Cleaning Information > Page 7540 Use appropriate eye protection. 4. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Important Position the valve body as shown in the following illustrations for positive identification and location of individual parts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - Control Valve/Solenoid Cleaning Information > Page 7541 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - Control Valve/Solenoid Cleaning Information > Page 7542 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - Control Valve/Solenoid Cleaning Information > Page 7543 Control Valve Body Spring, Bolt, Bore Plug and Retainer Identification Chart (Metric) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - Control Valve/Solenoid Cleaning Information > Page 7544 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - Control Valve/Solenoid Cleaning Information > Page 7545 Control Valve Body Spring, Bolt, Bore Plug and Retainer Identification Chart (Inch) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Valve Body: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Case and Associated Parts (2 of 2) 38 - Transmission Case Plug - Accumulator Bleed 39 - Pressure Plug 40 - Third Accumulator (#7) Retainer and Ball Assembly 41 - Band Anchor Pin 42 - Retainer and Ball Assembly - Double Orifice (#10) 43 - Accumulator Piston Pin 44 - 3-4 Accumulator Piston 45 - Oil Seal Ring - 3-4 Accumulator Piston 46 - 3-4 Accumulator Spring - Model Dependent Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7548 48 - Valve Body Spacer Plate w/Gasket - Bonded 53 - Spacer Plate Support Plate 54 - 1-2 Accumulator Spring - Outer - Model Dependent 55 - Oil Seal Ring - 1-2 Accumulator 56 - 1-2 Accumulator Piston 57 - 1-2 Accumulator Cover and Pin Assembly - Model Dependent 58 Accumulator Cover Bolt 59 - Accumulator Cover Bolt 60 - Control Body Valve Assembly - Model Dependent 61 - Checkball (#2, 3, 4, 5, 6, 8, 12) 62 - Valve Body Bolt 63 - Manual Detent Spring Assembly 64 - Manual Detent Spring Bolt 65 - Wiring Harness Pass-Through Connector O-Ring Seal 66 - Wiring Harness Solenoid Assembly - Model Dependent 67 - O-Ring Seal - Solenoid 68 Hex Washer Head Bolt - Solenoid 77 - Spacer Plate Support Bolt 77 - Spacer Plate Support Bolt 91 - Number 1 Checkball 103 - Main Section Case - Model Dependent 104 - 1-2 Accumulator Spring Inner 120 - Valve Body Bolt Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7549 Valve Body: Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Ball Check Valve Locations Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Valve Body: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control Valve Body Replacement Removal Procedure 1. Remove the fluid level indicator. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the oil pan, gasket, and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 4. Disconnect all the internal wiring harness electrical connectors from the electrical connectors (1-6) components. 5. Remove the torque converter clutch (TCC) pulse width modulation (PWM) solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 6. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7552 7. Remove the TCC solenoid retaining bolts (68). 8. Remove the TCC solenoid (with O-ring seal) and wiring harness (66) from the control valve body. 9. Reposition the harness to the side of the transmission case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7553 10. Remove the manual detent spring bolt (64) and the spring assembly (63). 11. Remove all valve body bolts. 12. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. Installation Procedure 1. Install the checkballs (1-7) in the valve body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7554 2. Install the control valve body (1) to the transmission case while simultaneously connecting the manual valve link to the manual valve. 3. Verify that the manual valve link is installed properly to the inside detent lever and the manual valve. 4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7555 5. Install the 12 valve body bolts (62), 2 bolts (59) and 3 bolts (120) that are shown only. 6. Finger tighten the bolts. 7. Install the transmission wiring harness on the valve body. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the TCC solenoid valve and bolts (68). Tighten the bolts to 8-14 Nm (6-10 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7556 Caution: Do not over-tighten the bolts. Over-tightening the bolts will distort the valve bores. Begin tightening from the center of the valve body tighten the bolts in a outward direction. 9. Inspect the ensure all of the valve body bolts are in the correct location. Each bolt number refers to a specific size, as indicated in the following list: * 59 M6 x 1.0 x 35.0 (Qty: 2) * 62 M6 x 1.0 x 47.5 (Qty: 12) * 120 M6 x 1.0 x 54.4 (Qty: 3) 10. Tighten the bolts from the center of the valve body working your way out in a spiral pattern to the outside edge. Tighten the bolts to 8-14 Nm (6-10 lb ft). 11. Install the TCC PWM solenoid valve (396) and the solenoid retainer (395). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7557 12. Snap the wiring harness in place on the valve body bolts. Ensure the harness loom tab is located under the transmission fluid pressure (TFP) switch. 13. Install the wiring connectors to the electrical components (1-6) as indicated in the following list: 1. The manual shift detent lever with shaft position switch assembly 2. The 1-2 shift solenoid 3. The 2-3 shift solenoid 4. The pressure control solenoid (PCS) 5. The TCC PWM solenoid 6. The input speed sensor (ISS) 14. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 15. Lower the vehicle. 16. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 17. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM) (See: Description and Operation/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Adaptive Functions (TCM)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7558 Valve Body: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Control Valve Lower Body and Upper Body Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 7559 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs Technical Service Bulletin # 08-07-30-021E Date: 100607 Electrical - Electrical Malfunction/Multiple DTCs TECHNICAL Bulletin No.: 08-07-30-021E Date: June 07, 2010 Subject: Loss of High Speed GMLAN Communications, Intermittent No Crank, IP Gage Fluctuation, Intermittent Door Lock Cycling, Intermittent Chime Operation, Various IP Warning Lamps Illuminated, Transmission May Not Shift, Communication DTCs U0073, U0100, U0101, U0102, U0109, U0121 or U0140 Set (Repair Backed Out Terminal in Transmission Harness Connector, Repair Open or Shorted GM High Speed LAN Circuits, Open or Shorted Data Link Resistor, Correct Corrosion or Poor Connections in Various Control Module Connectors) Models: 2007-2010 Cadillac Escalade Models, XLR 2009-2010 Cadillac Escalade Hybrid 2007-2010 Chevrolet Avalanche, Corvette, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Silverado Hybrid, Tahoe Hybrid 2007-2010 GMC Sierra, Yukon Models 2008-2010 GMC Sierra Hybrid, Yukon Hybrid 2008-2009 HUMMER H2 Equipped With 6 Speed 6L80 (RPO MYC) or 6L90 (RPO MYD) or Hybrid Two Mode 2ML70 Automatic Transmission Please Refer to GMVIS Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please discard Corporate Bulletin Number 08-07-30-021D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: - Instrument panel cluster (IPC) warning lamps may illuminate. - The transmission may not shift or defaults to 2nd gear. - The door locks may cycle by themselves. - The engine may not crank intermittently. - A driver information center (DIC) message is displayed. - The IPC gages may fluctuate. - Applying the brakes may cause the IPC to become erratic and the chimes to operate simultaneously. Depending on the vehicle, technicians may find one or more of the following High Speed GMLAN Communications DTCs set as Current or History: - U0073: Control Module Communications Bus OFF - U0100: Lost Communication With ECM/PCM - U0101: Lost Communication With TCM - U0102: Lost Communication With Transfer Case Control Module - U0109: Lost Communication With Fuel Pump Control Module - U0121: Lost Communication With ABS Control Module - U0140: Lost Communication With Body Control Module (BCM) Cause These conditions may be caused by, but not limited to, any of the following: - The terminal(s) for the High Speed GMLAN Serial Data Bus has backed out of the 16-way electrical connector to the automatic transmission. - The terminal position assurance (TPA) lock in the transmission 16-way electrical connector is not fully seated. - The High Speed GMLAN Serial Data Bus circuits are open or shorted to ground. - Corrosion in various control module connectors. - Intermittent or poor connections in the inline connectors containing the High Speed GMLAN Serial Data Bus circuits. - The data link resistor is open or shorted. - Water intrusion in various control module connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7568 Parts Information Warranty Information For transmission electrical repairs please note in the technicians comments field on the repair order which terminal number(s) were repaired or replaced. Also if a male terminal is bent (transmission side of connector), then indicate the bent terminal number on the repair order. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7569 Procedures to Diagnose/Chafed Wiring Harness at Trans Case Information for the Procedures to Diagnose and Repair the Above Conditions 1. Perform the Diagnostic System Check-Vehicle to begin your diagnosis of these conditions. 2. Perform a thorough visual inspection of the vehicle. 3. Depending on the vehicle, some of the procedures may not be applicable. 4. The following procedure is the only one applicable to the Corvette and XLR. Chafed Wiring Harness at Transmission Case Retaining Clip and Inspection of the 16-way Electrical Connector for Backed Out Terminals 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Locate the 16-way electrical connector on the right side of the automatic transmission as shown. 5. Inspect for a pinched/cut wiring harness where it is attached at the transmission by a metal attachment clip as shown. Inspect any of these harness clips that you may observe as needed. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7570 7. Before disconnecting the 16-way connector, inspect for any backed out terminals (2) as shown. Fully seated terminals (1) are shown for comparison. 1. If a backed out terminal (2) is found, identify the terminal(s) on the repair order. 2. Look at the connector in order to identify the number of the cavity with the backed out terminal. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List in SI. 8. Use the following procedure to disconnect the 16-way electrical connector: 1. For 2ML70 Only: Disconnect the 24-way electrical connector. 2. Release and hold the slide lock on the wiring harness connector. 3. Rotate the connector lever and remove the connector from the component. 9. Repair or replace the terminal(s) as necessary using the following procedure: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7571 1. Locate the terminal position assurance (TPA) as shown. Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 2. Use a small flat blade tool to push the TPA until it bottoms out. 3. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Note If the female terminal(s) must be replaced, it is part number 22124472200. It is located in Yazaki tray number 12 in the J-38125 Terminal Repair Kit. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7572 5. Repair or replace the terminal(s) as needed. Refer to the instructions in the J-38125 manual. 10. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 11. Slide the new terminal(s) into the correct cavity at the back of the connector until it locks in place. The new terminal(s) should be even with the other terminal(s). 12. Ensure that each terminal is locked in place by gently pulling on the wire. Note The male terminal(s) cannot be repaired as they are an integral part of the transmission control module (TCM). 13. Inspect for bent or misaligned terminal(s) in the transmission half of the electrical connector. ‹› If they are bent, use a suitable tool and apply gentle pressure to straighten them. Indicate on the repair order the terminal number of the male terminal that was bent. ‹› If they are damaged, refer to Control Solenoid Valve and Transmission Control Module Assembly Replacement in SI. 14. Prior to installing the transmission connector, perform the following steps to ensure that the TPA lock is fully seated. Locate the TPA lock in the reassembled transmission connector. Refer to the arrow in the illustration above, which points to a TPA lock. This one is in an unseated position. Using a small flat blade tool, push to seat the TPA until it bottoms out. Verify the TPA is fully seated. - If the TPA is off-center in the check window as shown, then it is only partially seated. Note the large gap at the arrow. Reseat the TPA lock and ensure that it is fully seated. - If the TPA lock is centered in the window as shown, then it is fully seated. The gaps shown by the arrows should be even on both sides. 15. Install the transmission 16-way electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7573 16. Lower the vehicle. 17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 18. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Fuse Block Inspection of Fuse Block - I/P (Left Side) for Loose Connector X1 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Disconnect Caution and Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side fuse block as shown. 4. Inspect connector X1 (1) on the back of the fuse block for a loose connection as shown. Secure the connector as needed. 5. Install the left side fuse block. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness Near Park Brake Pedal Assembly Chafed IP Wiring Harness Near Park Brake Pedal Assembly The above condition may cause one or more of the following fuses to open: - 60A - MBEC1 (#72) (Underhood) - 30A - AMP (#40) (Underhood) - 15A - RDO (#41) (Underhood) - 10A - IPC (#46) (Underhood) - 15A - AIRBAG BATT (#51) (Underhood) - 10A - DSM (Left side of IP) Five Areas of Potential Contact Have Been Identified Five areas of potential contact have been identified: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7574 - The IP wiring branch to C202 may have been routed outboard of the junction block (left IP) and the retaining clip (1) off the branch may not have been fully seated. Possible point of contact (2). - The IP wiring branch to C202 may have been pushed up and forward into the park brake assembly and the retaining clip off the branch may not have been fully seated. Possible points of contact (1, 2). - The IP wiring branch to C202 may have never been secured into place as the gray retaining clip (1) off the branch was never seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7575 - The IP harness may be in hard contact with the top rear edge (1) of the park brake assembly. - When releasing the park brake pedal, the moving part (1) at the end of the park brake release cable may be coming into hard contact with the IP harness. If a condition is suspected/found with one of the circuits running to C1 or C2 of the junction block or to the inline IP-to-body connector (C202) or at any of these areas of concern then remove the front driver side door sill plate, driver side body hinge pillar trim panel, left IP outer trim cover and perform the following steps: 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Visually inspect the IP harness for damage at the park brake pedal assembly. Refer to potential damage points shown in the photos at the side and rear of the park brake assembly. Note that damage may be hidden from view. The harness may be turned away from you, or covered by electrical tape. 4. Operate the park brake release lever. Observe the moving part at the end of the park brake release cable as it may contact and damage the IP harness. Inspect the IP harness at this point. Note that the damage may be hidden from view by electrical tape. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. If the harness is still in contact with a sharp edge or point of the park brake assembly, route it away from the contact point and secure it with tie straps. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7576 7. Inspect how the IP branch to C202 is routed. Reroute the harness as necessary to match the correct routing in the photo as shown. In order to route the IP harness branch correctly (behind the junction block-left I/P), remove the cover from the junction block-left I/P, unseat the junction block from the bracket. 8. Disconnect C202. Route the harness such that it lies between the "goalposts" of the junction block bracket. Seat the junction block to the bracket (harness will now be under the junction block). 9. Secure the harness by seating the grey offset retaining clip to the dashmat (or brown "buddy clip" if present - usually on SUV's only). Reconnect C202. 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 11. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness at Left Side Junction Block Mounting Bracket 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 4. Inspect for chafed/shorted wiring at the mounting bracket. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Replace the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 8. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Adjustable Pedals Motor 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Inspect the wiring harness for chafed/shorted wiring at the adjustable pedals motor as shown. 4. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Transmission 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Support the transmission with a transmission jack. 5. Remove the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7577 6. Lower the transmission sufficiently to provide access to the engine wiring harness where it routes from the engine intake manifold to the transmission bell housing as shown. 7. Release the wiring harness conduit from the retainers that secure it to the transmission and/or transfer case. Note IT WILL be necessary to extract the wiring harness from the protective conduit if chafing IS NOT observed on exposed wiring. 8. Examine the harness for wiring that may be exposed outside of the conduit. Inspect ALL areas for chafing as shown. If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 9. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 10. Raise the transmission as needed to install the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. 11. Lower the vehicle. 12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 13. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Engine Intake Manifold 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7578 4. Release the wiring harness conduit from the retainers that secure it to the rear of the engine and at the top of the transmission bell housing. Note The engine intake manifold is shown removed to provide clarity. 5. Pull the wiring harness up gently at the rear of the engine (1) and inspect the wiring harness for chafed/shorted wiring (2). If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing (1) or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 7. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Chassis Body Mounts Left Side Frame Rail 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7579 4. Inspect the wiring harness along the left side frame rail at the body mounts for chafed/shorted wiring as shown. 5. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 7. Lower the vehicle. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness Near Data Link Resistor Chafed Wiring Harness Near Data Link Resistor Causing Intermittent No/Crank and/or Scan Tool Does Not Communicate with High Speed GMLAN Device 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Typical location of a data link resistor (3) mounted on the chassis. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7580 5. Inspect the wiring harness near the data link resistor, between the truck box and frame for chafed/shorted wiring as shown. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > Data Link Resistor in SI. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Disconnect the electrical connector from the data link resistor. 7. Test the resistor for 110-130ohm. ‹› If not within the specified range, replace the data link resistor. ‹› If within the specified range, refer to Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. 8. Connect the electrical connector to the data link resistor. Secure the resistor as needed. 9. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 10. Lower the vehicle. 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 12. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Inspection of Engine Harness Connector X109 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X109 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X109 in SI. 4. Before disconnecting, verify the connector is fully seated together even though the lever is locked down as shown. If the connector is not fully seated, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Connector Repairs in SI. 5. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Connector X115 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7581 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X115 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X115 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 6. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Hybrid Models Chafed Wiring Harness Locations/Inspections Hybrid Models (HP2) Chafed Wiring Harness Locations and Inspection of Engine Harness Connector X150 for Backed Out Terminals and Poor Connections at Ground Locations G102 and G300 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X150 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X150 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the connector repair. 5. Inspect for a misrouted/chafed harness rubbing on the cooling fins of the Transmission Auxiliary Fluid Pump Control Module as shown. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Inspect for a chafed harness caused by a mispositioned retaining clip as shown. The chafing condition usually occurs when the tab of the clip is aligned with a slot in the conduit. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 7. Locate ground connections G102 and G300. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > G102 and G300 in SI. 8. Inspect G102 and G300 for a clean and tight connection. Undercoating has been found between the eyelet and the frame resulting in a poor connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7582 If a condition is found, clean the area and repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Lost Communication With DTC's Set Lost Communication with Various Control Modules and DTCs Set DTC Descriptors Note Depending on the vehicle there may be other DTCs set by other modules. - DTC U0073 Control Module Communication Bus A Off - DTC U0100 Lost Communication with Engine/Powertrain Control Module (ECM/PCM) - DTC U0101 Lost Communication with Transmission Control Module (TCM) - DTC U0102 Lost Communication with Transfer Case Control Module - DTC U0121 Lost Communication with Electronic Brake Control Module (EBCM) - DTC U0140 Lost Communication with Body Control Module (BCM) 1. Connect a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). If any DTC(s) are set, refer to the list above or the Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. Turn OFF the ignition and all accessories. 3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 4. Disconnect the connector(s) at the affected module. 5. Inspect the connector(s) for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) - Water intrusion ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI AND ‹› If corrosion or water intrusion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Reconnect the connector(s) at the affected modules. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Repairing Fretting Corrosion Repairing Fretting Corrosion Note Fretting corrosion looks like little dark smudges on the electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. 1. If any water intrusion is present in the connector, use pressure regulated compressed air to dry it out. 2. DO NOT apply an excessive amount of dielectric lubricant as shown, to the connectors as hydrolock may result when attempting to mate the connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7583 Important Use ONLY a clean nylon brush that is DEDICATED to the repair of this specific condition. With a one-inch nylon bristle brush, apply dielectric lubricant P/N 12377900 (in Canada, 10953529 to both the module/component side and the harness side of the affected connector(s). 3. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 4. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs Technical Service Bulletin # 08-07-30-021E Date: 100607 Electrical - Electrical Malfunction/Multiple DTCs TECHNICAL Bulletin No.: 08-07-30-021E Date: June 07, 2010 Subject: Loss of High Speed GMLAN Communications, Intermittent No Crank, IP Gage Fluctuation, Intermittent Door Lock Cycling, Intermittent Chime Operation, Various IP Warning Lamps Illuminated, Transmission May Not Shift, Communication DTCs U0073, U0100, U0101, U0102, U0109, U0121 or U0140 Set (Repair Backed Out Terminal in Transmission Harness Connector, Repair Open or Shorted GM High Speed LAN Circuits, Open or Shorted Data Link Resistor, Correct Corrosion or Poor Connections in Various Control Module Connectors) Models: 2007-2010 Cadillac Escalade Models, XLR 2009-2010 Cadillac Escalade Hybrid 2007-2010 Chevrolet Avalanche, Corvette, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Silverado Hybrid, Tahoe Hybrid 2007-2010 GMC Sierra, Yukon Models 2008-2010 GMC Sierra Hybrid, Yukon Hybrid 2008-2009 HUMMER H2 Equipped With 6 Speed 6L80 (RPO MYC) or 6L90 (RPO MYD) or Hybrid Two Mode 2ML70 Automatic Transmission Please Refer to GMVIS Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please discard Corporate Bulletin Number 08-07-30-021D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: - Instrument panel cluster (IPC) warning lamps may illuminate. - The transmission may not shift or defaults to 2nd gear. - The door locks may cycle by themselves. - The engine may not crank intermittently. - A driver information center (DIC) message is displayed. - The IPC gages may fluctuate. - Applying the brakes may cause the IPC to become erratic and the chimes to operate simultaneously. Depending on the vehicle, technicians may find one or more of the following High Speed GMLAN Communications DTCs set as Current or History: - U0073: Control Module Communications Bus OFF - U0100: Lost Communication With ECM/PCM - U0101: Lost Communication With TCM - U0102: Lost Communication With Transfer Case Control Module - U0109: Lost Communication With Fuel Pump Control Module - U0121: Lost Communication With ABS Control Module - U0140: Lost Communication With Body Control Module (BCM) Cause These conditions may be caused by, but not limited to, any of the following: - The terminal(s) for the High Speed GMLAN Serial Data Bus has backed out of the 16-way electrical connector to the automatic transmission. - The terminal position assurance (TPA) lock in the transmission 16-way electrical connector is not fully seated. - The High Speed GMLAN Serial Data Bus circuits are open or shorted to ground. - Corrosion in various control module connectors. - Intermittent or poor connections in the inline connectors containing the High Speed GMLAN Serial Data Bus circuits. - The data link resistor is open or shorted. - Water intrusion in various control module connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7589 Parts Information Warranty Information For transmission electrical repairs please note in the technicians comments field on the repair order which terminal number(s) were repaired or replaced. Also if a male terminal is bent (transmission side of connector), then indicate the bent terminal number on the repair order. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7590 Procedures to Diagnose/Chafed Wiring Harness at Trans Case Information for the Procedures to Diagnose and Repair the Above Conditions 1. Perform the Diagnostic System Check-Vehicle to begin your diagnosis of these conditions. 2. Perform a thorough visual inspection of the vehicle. 3. Depending on the vehicle, some of the procedures may not be applicable. 4. The following procedure is the only one applicable to the Corvette and XLR. Chafed Wiring Harness at Transmission Case Retaining Clip and Inspection of the 16-way Electrical Connector for Backed Out Terminals 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Locate the 16-way electrical connector on the right side of the automatic transmission as shown. 5. Inspect for a pinched/cut wiring harness where it is attached at the transmission by a metal attachment clip as shown. Inspect any of these harness clips that you may observe as needed. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7591 7. Before disconnecting the 16-way connector, inspect for any backed out terminals (2) as shown. Fully seated terminals (1) are shown for comparison. 1. If a backed out terminal (2) is found, identify the terminal(s) on the repair order. 2. Look at the connector in order to identify the number of the cavity with the backed out terminal. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List in SI. 8. Use the following procedure to disconnect the 16-way electrical connector: 1. For 2ML70 Only: Disconnect the 24-way electrical connector. 2. Release and hold the slide lock on the wiring harness connector. 3. Rotate the connector lever and remove the connector from the component. 9. Repair or replace the terminal(s) as necessary using the following procedure: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7592 1. Locate the terminal position assurance (TPA) as shown. Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 2. Use a small flat blade tool to push the TPA until it bottoms out. 3. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Note If the female terminal(s) must be replaced, it is part number 22124472200. It is located in Yazaki tray number 12 in the J-38125 Terminal Repair Kit. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7593 5. Repair or replace the terminal(s) as needed. Refer to the instructions in the J-38125 manual. 10. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 11. Slide the new terminal(s) into the correct cavity at the back of the connector until it locks in place. The new terminal(s) should be even with the other terminal(s). 12. Ensure that each terminal is locked in place by gently pulling on the wire. Note The male terminal(s) cannot be repaired as they are an integral part of the transmission control module (TCM). 13. Inspect for bent or misaligned terminal(s) in the transmission half of the electrical connector. ‹› If they are bent, use a suitable tool and apply gentle pressure to straighten them. Indicate on the repair order the terminal number of the male terminal that was bent. ‹› If they are damaged, refer to Control Solenoid Valve and Transmission Control Module Assembly Replacement in SI. 14. Prior to installing the transmission connector, perform the following steps to ensure that the TPA lock is fully seated. Locate the TPA lock in the reassembled transmission connector. Refer to the arrow in the illustration above, which points to a TPA lock. This one is in an unseated position. Using a small flat blade tool, push to seat the TPA until it bottoms out. Verify the TPA is fully seated. - If the TPA is off-center in the check window as shown, then it is only partially seated. Note the large gap at the arrow. Reseat the TPA lock and ensure that it is fully seated. - If the TPA lock is centered in the window as shown, then it is fully seated. The gaps shown by the arrows should be even on both sides. 15. Install the transmission 16-way electrical connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7594 16. Lower the vehicle. 17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 18. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Fuse Block Inspection of Fuse Block - I/P (Left Side) for Loose Connector X1 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Disconnect Caution and Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side fuse block as shown. 4. Inspect connector X1 (1) on the back of the fuse block for a loose connection as shown. Secure the connector as needed. 5. Install the left side fuse block. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness Near Park Brake Pedal Assembly Chafed IP Wiring Harness Near Park Brake Pedal Assembly The above condition may cause one or more of the following fuses to open: - 60A - MBEC1 (#72) (Underhood) - 30A - AMP (#40) (Underhood) - 15A - RDO (#41) (Underhood) - 10A - IPC (#46) (Underhood) - 15A - AIRBAG BATT (#51) (Underhood) - 10A - DSM (Left side of IP) Five Areas of Potential Contact Have Been Identified Five areas of potential contact have been identified: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7595 - The IP wiring branch to C202 may have been routed outboard of the junction block (left IP) and the retaining clip (1) off the branch may not have been fully seated. Possible point of contact (2). - The IP wiring branch to C202 may have been pushed up and forward into the park brake assembly and the retaining clip off the branch may not have been fully seated. Possible points of contact (1, 2). - The IP wiring branch to C202 may have never been secured into place as the gray retaining clip (1) off the branch was never seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7596 - The IP harness may be in hard contact with the top rear edge (1) of the park brake assembly. - When releasing the park brake pedal, the moving part (1) at the end of the park brake release cable may be coming into hard contact with the IP harness. If a condition is suspected/found with one of the circuits running to C1 or C2 of the junction block or to the inline IP-to-body connector (C202) or at any of these areas of concern then remove the front driver side door sill plate, driver side body hinge pillar trim panel, left IP outer trim cover and perform the following steps: 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Visually inspect the IP harness for damage at the park brake pedal assembly. Refer to potential damage points shown in the photos at the side and rear of the park brake assembly. Note that damage may be hidden from view. The harness may be turned away from you, or covered by electrical tape. 4. Operate the park brake release lever. Observe the moving part at the end of the park brake release cable as it may contact and damage the IP harness. Inspect the IP harness at this point. Note that the damage may be hidden from view by electrical tape. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. If the harness is still in contact with a sharp edge or point of the park brake assembly, route it away from the contact point and secure it with tie straps. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7597 7. Inspect how the IP branch to C202 is routed. Reroute the harness as necessary to match the correct routing in the photo as shown. In order to route the IP harness branch correctly (behind the junction block-left I/P), remove the cover from the junction block-left I/P, unseat the junction block from the bracket. 8. Disconnect C202. Route the harness such that it lies between the "goalposts" of the junction block bracket. Seat the junction block to the bracket (harness will now be under the junction block). 9. Secure the harness by seating the grey offset retaining clip to the dashmat (or brown "buddy clip" if present - usually on SUV's only). Reconnect C202. 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 11. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness at Left Side Junction Block Mounting Bracket 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 4. Inspect for chafed/shorted wiring at the mounting bracket. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Replace the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 8. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Adjustable Pedals Motor 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Inspect the wiring harness for chafed/shorted wiring at the adjustable pedals motor as shown. 4. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Transmission 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Support the transmission with a transmission jack. 5. Remove the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7598 6. Lower the transmission sufficiently to provide access to the engine wiring harness where it routes from the engine intake manifold to the transmission bell housing as shown. 7. Release the wiring harness conduit from the retainers that secure it to the transmission and/or transfer case. Note IT WILL be necessary to extract the wiring harness from the protective conduit if chafing IS NOT observed on exposed wiring. 8. Examine the harness for wiring that may be exposed outside of the conduit. Inspect ALL areas for chafing as shown. If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 9. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 10. Raise the transmission as needed to install the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. 11. Lower the vehicle. 12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 13. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Engine Intake Manifold 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7599 4. Release the wiring harness conduit from the retainers that secure it to the rear of the engine and at the top of the transmission bell housing. Note The engine intake manifold is shown removed to provide clarity. 5. Pull the wiring harness up gently at the rear of the engine (1) and inspect the wiring harness for chafed/shorted wiring (2). If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing (1) or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 7. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Chassis Body Mounts Left Side Frame Rail 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7600 4. Inspect the wiring harness along the left side frame rail at the body mounts for chafed/shorted wiring as shown. 5. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 7. Lower the vehicle. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness Near Data Link Resistor Chafed Wiring Harness Near Data Link Resistor Causing Intermittent No/Crank and/or Scan Tool Does Not Communicate with High Speed GMLAN Device 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Typical location of a data link resistor (3) mounted on the chassis. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7601 5. Inspect the wiring harness near the data link resistor, between the truck box and frame for chafed/shorted wiring as shown. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > Data Link Resistor in SI. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Disconnect the electrical connector from the data link resistor. 7. Test the resistor for 110-130ohm. ‹› If not within the specified range, replace the data link resistor. ‹› If within the specified range, refer to Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. 8. Connect the electrical connector to the data link resistor. Secure the resistor as needed. 9. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 10. Lower the vehicle. 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 12. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Inspection of Engine Harness Connector X109 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X109 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X109 in SI. 4. Before disconnecting, verify the connector is fully seated together even though the lever is locked down as shown. If the connector is not fully seated, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Connector Repairs in SI. 5. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Connector X115 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7602 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X115 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X115 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 6. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Hybrid Models Chafed Wiring Harness Locations/Inspections Hybrid Models (HP2) Chafed Wiring Harness Locations and Inspection of Engine Harness Connector X150 for Backed Out Terminals and Poor Connections at Ground Locations G102 and G300 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X150 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X150 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the connector repair. 5. Inspect for a misrouted/chafed harness rubbing on the cooling fins of the Transmission Auxiliary Fluid Pump Control Module as shown. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Inspect for a chafed harness caused by a mispositioned retaining clip as shown. The chafing condition usually occurs when the tab of the clip is aligned with a slot in the conduit. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 7. Locate ground connections G102 and G300. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > G102 and G300 in SI. 8. Inspect G102 and G300 for a clean and tight connection. Undercoating has been found between the eyelet and the frame resulting in a poor connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7603 If a condition is found, clean the area and repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Lost Communication With DTC's Set Lost Communication with Various Control Modules and DTCs Set DTC Descriptors Note Depending on the vehicle there may be other DTCs set by other modules. - DTC U0073 Control Module Communication Bus A Off - DTC U0100 Lost Communication with Engine/Powertrain Control Module (ECM/PCM) - DTC U0101 Lost Communication with Transmission Control Module (TCM) - DTC U0102 Lost Communication with Transfer Case Control Module - DTC U0121 Lost Communication with Electronic Brake Control Module (EBCM) - DTC U0140 Lost Communication with Body Control Module (BCM) 1. Connect a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). If any DTC(s) are set, refer to the list above or the Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. Turn OFF the ignition and all accessories. 3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 4. Disconnect the connector(s) at the affected module. 5. Inspect the connector(s) for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) - Water intrusion ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI AND ‹› If corrosion or water intrusion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Reconnect the connector(s) at the affected modules. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Repairing Fretting Corrosion Repairing Fretting Corrosion Note Fretting corrosion looks like little dark smudges on the electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. 1. If any water intrusion is present in the connector, use pressure regulated compressed air to dry it out. 2. DO NOT apply an excessive amount of dielectric lubricant as shown, to the connectors as hydrolock may result when attempting to mate the connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 7604 Important Use ONLY a clean nylon brush that is DEDICATED to the repair of this specific condition. With a one-inch nylon bristle brush, apply dielectric lubricant P/N 12377900 (in Canada, 10953529 to both the module/component side and the harness side of the affected connector(s). 3. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 4. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 7605 Wiring Harness: Service and Repair Wiring Harness Replacement Special Tools * J 44247 Internal Wiring Harness Installer * J 44257 Main Wiring Harness Connector Remover Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Remove the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (). 2. Disconnect the external wiring harness from the main transmission connector. Use J 44257 , if connector is not easily accessible. Note: The main transmission connector is actually one end of the internal wiring harness that protrudes through the transmission case. 3. Place a 30 mm or 1 3/16 inch 12-point deep socket or box-end wrench (2) over the main transmission connector (1). 4. Push inward on the socket or wrench to release the retaining feet that attach the connector (1) to the transmission case. 5. Remove the wrench. Push inward on the electrical connector to separate from the transmission case. 6. Disconnect the internal wiring harness connectors (1) from the solenoids, the internal mode switch (IMS), and from the transmission fluid pressure (TFP) switch. Note: The solenoid retainers for shift solenoid 3 (SS3) and shift solenoid 2 (SS2) also retain tabs on the wiring harness U-channel. The solenoids will remain in position even after the solenoid retainers are removed. 7. Remove the solenoid retainers (2) for SS3 and SS2. 8. Remove the internal wiring harness from the transmission. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 7606 1. Align the tabs on the new wiring harness (10) U-channel with the solenoid retainer slots for SS3 (3) and SS2 (2) on the control valve assembly. Install the solenoid retainers (12) for the SS3 (3) and SS2 (2) solenoids. Note: The internal wiring harness connectors should be in the correct position for installation because of their pre-assembled position in the U-channel. 2. Attach the internal wiring harness (10) connectors to the solenoids, the IMS, and the TFP switch. * Connector (8) goes to SS1 (5) * Connector (9) goes to the TFP switch (7) * Connector (11) goes to the MAIN MOD solenoid (19) * Connector (13) goes to the IMS * Connector (14) goes to the TCC PCS (1) * Connector (15) goes to SS2 (2) * Connector (16) goes to SS3 (3) * Connector (17) goes to PCS1 (4) * Connector (18) goes to PCS2 (6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 7607 3. Push the main transmission connector outward through hole in the transmission case until the retaining feet on the connector are near the locked position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 7608 4. Use J 44247 to seat the retaining feet on transmission connector (1). 5. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (). 6. Connect the external wiring harness to the main transmission connector. Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Refer to FastLearn Procedure (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair Clutch Disc: Service and Repair Clutch Assembly Replacement Special Tools J 5824-A Clutch Alignment Tool Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Tremec 5-Speed (TZ0) - Manual Transmission/Transmission Replacement). 2. Remove the clutch pressure plate bolts. Note: Dowel pins are used to align the flywheel and pressure plate. When removing the pressure plate check to see if the dowel pins are rusted into the pressure plate, if so remove, clean, and reinstall the dowel pins into the correct location(s) on the flywheel. 3. Remove the clutch pressure plate and disc from the dowel pins. Installation Procedure 1. If equipped with a 4.8L or 6.0L engine, install the clutch pressure plate and driven plate to the dowel pins. 2. Install J 5824-A in order to align the clutch. 3. Install the clutch pressure plate bolts finger tight. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 7613 4. If equipped with a 4.8L or 6.0L engine, tighten the clutch pressure plate bolts in the sequence shown. Tighten the bolts to 70 Nm (52 lb ft). 5. Remove the J 5824-A . 6. Install the transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Tremec 5-Speed (TZ0) - Manual Transmission/Transmission Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications HYDRAULIC CLUTCH FLUID GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair Clutch Master Cylinder: Service and Repair Clutch Master Cylinder Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Push the clutch pedal in and squeeze the pushrod bushing tabs in, in order to release the pushrod bushing from the clutch pedal. 3. Disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 4. Remove the clutch master cylinder clip from the brake pressure module valve pipe. 5. Rotate the clutch master cylinder 45 degrees clockwise to the unlocked position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 7621 6. Remove the clutch master cylinder. Installation Procedure 1. Install the clutch master cylinder. 2. Push in and rotate the clutch master cylinder 45 degrees counterclockwise to the locked position. 3. Disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 4. Install the clutch master cylinder clip to the brake pressure module valve pipe. 5. Apply light pressure to the clutch pedal to couple the pushrod socket to the clutch pedal. 6. Connect the clutch pedal position switch electrical connector (1). 7. Pump the clutch pedal 3 time prior to starting the vehicle to ensure connection is complete. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Clutch Actuator Cylinder Replacement (TZ0) Clutch Slave Cylinder: Service and Repair Clutch Actuator Cylinder Replacement (TZ0) Clutch Actuator Cylinder Replacement (TZ0) Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Push the clutch pedal in and squeeze the pushrod bushing tabs in, in order to release the pushrod bushing from the clutch pedal. 3. Disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 4. Remove the clutch master cylinder clip from the brake pressure module valve pipe. 5. Rotate the clutch master cylinder 45 degrees clockwise to the unlocked position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Clutch Actuator Cylinder Replacement (TZ0) > Page 7626 6. Remove the clutch master cylinder. Installation Procedure 1. Install the clutch master cylinder. 2. Push in and rotate the clutch master cylinder 45 degrees counterclockwise to the locked position. 3. Disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 4. Install the clutch master cylinder clip to the brake pressure module valve pipe. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Clutch Actuator Cylinder Replacement (TZ0) > Page 7627 5. Apply light pressure to the clutch pedal to couple the pushrod socket to the clutch pedal. 6. Connect the clutch pedal position switch electrical connector (1). 7. Pump the clutch pedal 3 time prior to starting the vehicle to ensure connection is complete. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Clutch Actuator Cylinder Replacement (TZ0) > Page 7628 Clutch Slave Cylinder: Service and Repair Clutch Actuator Cylinder Replacement (M96) Clutch Actuator Cylinder Replacement (M96) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair Clutch Pedal Assembly: Service and Repair Clutch Pedal Replacement Removal Procedure 1. Move the instrument panel to the service position. Refer to Instrument Panel Service Positioning (with SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (with SLT))Instrument Panel Service Positioning (without SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (without SLT)). 2. Disconnect the clutch pedal engine start switch electrical connector (1). 3. Remove the clutch master cylinder. Refer to Clutch Master Cylinder Replacement (See: Clutch Hydraulic System/Clutch Master Cylinder/Service and Repair). 4. Remove the clutch pedal to clutch pedal bracket bolt. 5. Remove the clutch pedal to brake module bolts. 6. Remove the clutch pedal sub-assembly. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Page 7632 1. Install the clutch pedal sub-assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the clutch pedal to brake module bolts. Tighten the bolts to 50 Nm (37 lb ft). 3. Install the clutch pedal to clutch pedal bracket bolt. Tighten the bolt to 36 Nm (27 lb ft). 4. Remove the clutch master cylinder. Refer to Clutch Master Cylinder Replacement (See: Clutch Hydraulic System/Clutch Master Cylinder/Service and Repair). 5. Connect the clutch pedal engine start switch electrical connector (1). 6. Install the instrument panel. Refer to Instrument Panel Service Positioning (with SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (with SLT))Instrument Panel Service Positioning (without SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (without SLT)). Warning Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Page 7633 7. Perform the clutch pedal position sensor learn procedure. Refer to Clutch Pedal Position Sensor Learn (See: Testing and Inspection/Programming and Relearning/Clutch Pedal Position Sensor Learn/Tremec 5-Speed (TZ0) - Manual Transmission) or Clutch Pedal Position Sensor Learn (See: Manual Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection Clutch Pedal Position Sensor Learn Important: The clutch pedal position (CPP) sensor learn procedure is required when the following service procedures have been performed regardless of whether DTC P080A is set: * An engine control module (ECM) replacement * A CPP sensor replacement * Any repairs which affect the CPP sensor relationship 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P080A, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select Clutch Pedal Position Learn under Module Setup in Manual Transmission, and perform the following instructions displayed on the scan tool screen. Important: The CPP sensor learn procedure cannot be performed more than once per ignition cycle. The clutch pedal needs to be fully depressed and held steady throughout this procedure in order to perform a correct learning. 4. The scan tool will display under CPP Learn Status: Not Learned, In Process, Complete, Fail Low Volt, Fail - High Volt, or Fail Moving. The scan tool will display under CPP Learn Status Complete if the process was successful. 5. If the scan tool indicates that DTC P080A ran and passed this ignition the CPP sensor learn procedure is complete. If the scan tool indicates DTC P080A failed or did not run this ignition, refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission). If any other DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC. 6. Turn OFF the ignition for 30 seconds after the learn procedure has successfully completed in order to store the CPP sensor variation values in ECM history. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 7637 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Engine Start Switch Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Remove the plastic retainer (1) tabs from the clutch pedal position switch (2). 3. Remove the clutch pedal position switch (2) from the pushrod. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 7638 1. Install the clutch pedal position switch (2) to the pushrod. 2. Install the plastic retainer (1) tabs to the clutch pedal position switch (2). 3. Connect the clutch pedal position switch electrical connector (1). Warning Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged. 4. Perform the clutch pedal position sensor learn procedure. Refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission) or Clutch Pedal Position Sensor Learn (See: Manual Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair Clutch Release Bearing: Service and Repair Release Bearing Replacement Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Tremec 5-Speed (TZ0) - Manual Transmission/Transmission Replacement). 2. Remove the clutch release bearing. * Rotate the bearing in either direction. * The compression spring load will push the release bearing off the end of the clutch actuator bearing. Installation Procedure Important: DO NOT use cleaners or chemicals to clean the quill and DO NOT grease the quill. 1. Using a clean dry cloth, clean the exposed area of the actuator cylinder quill. 2. Install the NEW clutch release bearing to the clutch actuator cylinder. * Firmly push the clutch release bearing into place. * The release bearing will snap over the retainer tab and will be self-retained to the actuator cylinder. 3. Install the transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Tremec 5-Speed (TZ0) - Manual Transmission/Transmission Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair Pilot Bearing: Service and Repair Clutch Pilot Bearing Replacement Special Tools * J 43276 Clutch Pilot Bearing Remover * J 38836 Bushing Installer/Clutch Arbor Removal Procedure Caution: When using the J 43276 Clutch Pilot Bearing Remover, always secure the J 43276-1 Clutch Pilot Bearing Remover tool body using a wrench. Do not allow the J 43276-1 tool body to rotate. Failing to do so causes damage to the J 43276-1 tool body. Note: The flywheel spacer (if applicable) must be removed prior to clutch pilot bearing removal. 1. Remove the clutch assembly. Refer to Clutch Assembly Replacement (See: Service and Repair). 2. Using J 43276 perform the following in order to remove the clutch pilot bearing: 1. Install the J 43276-1 into the clutch pilot bearing. 2. Using a wrench, secure the J 43276-1. 3. Insert the J 43276-2 into the J 43276-1. 4. Rotate the J 43276-2 clockwise into the J 43276-1 until the clutch pilot bearing is completely removed from the crankshaft. 5. Rotate the J 43276-2 counterclockwise to remove the J 43276-2 from the J 43276-1. 6. Remove the J 43276-1 from the tool body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 7645 3. Discard the old clutch pilot bearing. Installation Procedure Note: The flywheel spacer (if applicable) must be removed prior to pilot bearing installation. 1. Install a 5/8 inch washer (1) onto the J 38836 or equivalent. 2. Install a NEW clutch pilot bearing (2) onto the tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 7646 3. Install the NEW clutch pilot bearing into the crankshaft using J 38836 . 4. Inspect the clutch pilot bearing for proper installation. 5. Install the clutch assembly. Refer to Clutch Assembly Replacement (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Fastener Tightening Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 7650 Pressure Plate: Service and Repair Clutch Assembly Replacement Special Tools J 5824-A Clutch Alignment Tool Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Tremec 5-Speed (TZ0) - Manual Transmission/Transmission Replacement). 2. Remove the clutch pressure plate bolts. Note: Dowel pins are used to align the flywheel and pressure plate. When removing the pressure plate check to see if the dowel pins are rusted into the pressure plate, if so remove, clean, and reinstall the dowel pins into the correct location(s) on the flywheel. 3. Remove the clutch pressure plate and disc from the dowel pins. Installation Procedure 1. If equipped with a 4.8L or 6.0L engine, install the clutch pressure plate and driven plate to the dowel pins. 2. Install J 5824-A in order to align the clutch. 3. Install the clutch pressure plate bolts finger tight. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 7651 4. If equipped with a 4.8L or 6.0L engine, tighten the clutch pressure plate bolts in the sequence shown. Tighten the bolts to 70 Nm (52 lb ft). 5. Remove the J 5824-A . 6. Install the transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Tremec 5-Speed (TZ0) - Manual Transmission/Transmission Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information Continuously Variable Transmission/Transaxle: Technical Service Bulletins A/T Controls Snapshot Data Upload Information INFORMATION Bulletin No.: 07-07-30-010B Date: June 19, 2009 Subject: Procedure to Take Snapshot Data with a Tech 2(R) and Upload Data to a Computer Using TIS Software Models: 2004-2010 Passenger Cars and Light Duty Truck (Including Saturn; excluding Astra models) 2004-2010 HUMMER H2, H3 2004-2009 Saab 9-7X Supercede: This bulletin is being revised to update the Sending a Snapshot to GM TAC section and add the 2010 model year. Please discard Corporate Bulletin Number 07-07-30-010A (Section 07 - Transmission/Transaxle). Important Global Diagnostic System (GDS) will take the place of the Tech 2(R) on certain vehicles when communicating and diagnosing vehicle on-board electrical systems. This new diagnostic tool platform and software will be required for use with all GM Global Architecture (Global A) vehicles beginning with the 2010 Chevrolet Camaro, followed later by the Buick Allure/LaCrosse, Chevrolet Equinox, Cadillac SRX and the GMC Terrain. These vehicles will no longer permit Tech 2(R) communication for diagnostic purposes. For further information, refer to Corporate Bulletin Number 09-00-89-019 (Introduction of New Global Diagnostic System (GDS)). This procedure is intended to show the user how to take snapshot data with a Tech 2(R) and upload it to a computer. The procedure is written for an automatic transmission data snapshot on a Saturn AURA, but is similar for all applications. This procedure is written with the assumption the user has a basic understanding of how to use a Tech 2(R) already. Capturing a Snapshot of the Vehicle Data Stream 1. Connect the Tech 2(R) to the vehicle Data Link Connector (DLC) as shown above. Use a CANdi module as required. 2. Power up the Tech 2(R) and press the ENTER key at the start-up screen. 3. From the Main Menu select F0: Diagnostics. 4. Enter all vehicle information as requested on the scan tool's display. Bolded selections are vehicle specific. - Select "2007" - Select "Passenger Car (F0)" - Select "Saturn" Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 7656 - Select "Z" - Select "Aura" - Select "Powertrain" - Select "3.6L LY7" - Select "Transmission" - Select "Transmission Data" 5. From the application menu, select F3: Snapshot. - Choose trigger type and trigger point, as described above. - It is preferred to trigger on "Any Code" (F1) - If multiple codes are setting, select "Single Code" and enter the code you are trying to capture on the next screen. - Select "Center (F5)" for the trigger point. This allows the requester/viewer of the data to see the events before and after the code sets. 6. Press the Record Snapshot soft key. The Tech 2(R) screen will display the parameters it is going to record for live viewing. - When the fault occurs, the Tech 2(R) will automatically start recording if the preferred settings (F1 and F5) are selected. - If manual trigger is selected during the setup procedure, you will have to hit the "Trigger" soft key to actually record data. Otherwise, it will automatically start recording when a DTC is set. - Allow the Tech 2(R) to record the data. Please note that a Tech 2(R) can record a maximum of 1 minute of data (30 seconds before and 30 seconds after the trigger point if center trigger is selected). Important The Tech(R)2 can only record two snapshots prior to uploading to a computer. If a third snapshot is requested, the first snapshot will be overwritten. 7. When the snap shot data has been recorded, exit to the Main Menu, then power down and disconnect the Tech 2(R) from the vehicle. Uploading and Sending a Snapshot via TIS2WEB Figure 8 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 7657 Figure 9 1. Once TIS2WEB is launched and you're at the main screen, select Snapshot, indicated with a arrow in Figure 8. 2. Select the Upload from Handheld button to launch the device selection screen just like the TIS 2000 procedure described above. Figure 10 3. Select the top button, "Upload from Handheld" which will launch the screen displayed in Figure 10. Make sure the Tech 2(R) is connected to the computer and plugged in. Select Tech 2(R) under Device and select OK. The screen of your Tech 2(R) should start blinking and a line will start scrolling across the screen indicating it is communicating with your computer. Figure 11 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 7658 4. Once communication is established and you select the file you want to upload, you will see a screen similar to below. You can email the file directly from TIS2WEB by going to the Snapshot drop down menu and selecting "Send to e-mail" as shown in Figure 11. Figure 12 5. After selecting Send to e-mail, a dialog box like the one shown in Figure 12 will be displayed. Fill in the information as requested and then click send. Include the VIN in the subject line. 6. After all the information is entered, hit the send button. After sending the file, you will receive a confirmation box letting you know the e-mail was sent successfully. 7. It is recommended to now save the file to your computer using the same procedure as if you were using TIS 2000 in case your recipient doesn't receive your email with the snapshot data. Important Sending the file via e-mail through TIS2WEB does NOT save the file locally and there is no way to access your sent mail in TIS2WEB like a regular e-mail program. Sending a Snapshot to GM TAC Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 7659 During your call with GM TAC on a current case, you may be advised to send a copy of the Tech 2(R) or VDR Snapshot Data to the TAC e-mail box. U.S. Dealers - send to e-mail box [email protected] Canadian Dealers - send to e-mail box [email protected] Please complete the following: - Be sure to review the procedures listed above for uploading and sending a Snapshot via TIS2WEB. - If you are using a VDR to capture Snapshot Data, information can be accessed in the Techlink Website in the articles (December 2002, December 2003, July 2004 and January 2006). - Please be sure to identify the snapshot by placing the TAC Case Number, the last eight digits of the VIN and the type of data (i.e. engine or transmission) in the subject line of your e-mail. The email Subject Line MUST contain the TAC case number and last 8 digits of the VIN or their email can not be processed and will be deleted. Please send only REQUESTED Snapshot Data to the TAC e-mail box. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 7660 Continuously Variable Transmission/Transaxle: Technical Service Bulletins Vehicle - Engine Crankcase and Subsystems Flushing Info. INFORMATION Bulletin No.: 04-06-01-029E Date: April 29, 2010 Subject: Unnecessary Flushing Services, Additive Recommendations and Proper Utilization of GM Simplified Maintenance Schedule to Enhance Customer Service Experience Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add information about the proper transmission flush procedure. Please discard Corporate Bulletin Number 04-06-01-029D (Section 06 - Engine/Propulsion System). An Overview of Proper Vehicle Service General Motors is aware that some companies are marketing tools and equipment to support a subsystem flushing procedures. These dedicated machines are in addition to many engine oil, cooling system, fuel system, A/C, transmission flush and steering system additives available to the consumer. GM Vehicles under normal usage do not require any additional procedures or additives beyond what is advised under the former Vehicle Maintenance Schedules or the current Simplified Maintenance Schedules. Do not confuse machines available from Kent-Moore/SPX that are designed to aid and accelerate the process of fluid changing with these flushing machines. Engine Crankcase Flushing General Motors Corporation does not endorse or recommend engine crankcase flushing for any of its gasoline engines. Analysis of some of the aftermarket materials used for crankcase flushing indicate incompatibility with GM engine components and the potential for damage to some engine seals and bearings. Damage to engine components resulting from crankcase flushing IS NOT COVERED under the terms of the New Vehicle Warranty. GM Authorized Service Information: Detailed, Descriptive, and Complete If a specific model vehicle or powertrain need is identified, GM will issue an Authorized Service Document containing a procedure and, if required, provide, make available, or require the specific use of a machine, tool or chemical to accomplish proper vehicle servicing. An example of this is fuel injector cleaning. Due to variation in fuel quality in different areas of the country, GM has recognized the need for fuel injector cleaning methods on some engines, though under normal circumstances, this service is not part of the maintenance requirements. GM has published several gasoline fuel injector cleaning bulletins that fully outline the methods to be used in conjunction with GM Part Numbered solutions to accomplish proper and safe cleaning of the fuel injectors with preventative maintenance suggestions to maintain optimum performance. You may refer to Corporate Bulletin Numbers 03-06-04-030 and 04-06-04-051 for additional information on this subject. Subsystem Flushing Flushing of A/C lines, radiators, transmission coolers, and power steering systems are recognized practices to be performed after catastrophic failures or extreme corrosion when encountered in radiators. For acceptable A/C flushing concerns, refer to Corporate Bulletin Number 01-01-38-006. This practice is NOT required or recommended for normal service operations. The use of external transmission fluid exchange or flush machines is NOT recommended for the automatic or manual transmission. Use of external machines to replace the fluid may affect the operation or durability of the transmission. Transmission fluid should only be replaced by draining and refilling following directions in SI. Refer to Automatic/Manual Transmission Fluid and Filter Replacement. Approved Transmission Flushing Tool (Transmission Cooler Only) The Automatic Transmission Oil Cooler Flush and Flow Test Tool is recommended for GM vehicles. Refer to Transmission Fluid Cooler Flushing and Flow Test in SI using the J 45096. Service Is Important to You and Your Customer General Motors takes great pride in offering our dealerships and customers high quality vehicles that require extremely low maintenance over the life of the vehicle. This low cost of ownership builds repeat sales and offers our customers measurable economy of operation against competing vehicles. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 7661 Providing responsible services at the proper intervals will greatly aid your dealership with repeat business, and additional services when required. Most customers appreciate and gain trust in the dealership that informs and offers them just what they need for continued trouble-free operation. Examine your service department's practices and verify that all Service Consultants and Technicians focus on customer satisfaction, vehicle inspections, and other products at time of service. Use this opportunity to upgrade the services you provide to your customers. Here are a few suggestions: - Take the time required to align your dealership service practices with the new GM Simplified Maintenance Schedule. Use the new vehicle Owner's Manual Maintenance I and II schedules to create a "mirror image" in your advertising and dealer service pricing that is easily understandable to your customer. Taking advantage of this new service strategy may greatly increase your dealership service sales and customer retention while decreasing the frequency of visits and inconvenience to your customer. - Review your program to ensure that all vehicles coming in are evaluated for safety and wear items. Examine all vehicles for tire condition, signs of misalignment, brake wear, exterior lamp functionality, exhaust condition, A/C cooling performance, SRS or Air Bag MIL, along with Service Engine Soon or Check Engine indicators. If the Service Engine Soon or Check Engine MIL is illuminated, it is vital that you inform the customer of the concerns with ignoring the indicator and what the required repair would cost. In addition to the possibility of increased emissions and driveability concerns, many customers are unaware that lower gas mileage may also result, with additional cost to the customer. - Be complete in your service recommendations. Some sales opportunities are not being fully pursued nationally. Focus on overlooked but required maintenance that has real benefits to the customer. Many vehicles are equipped with cabin air filters. If these filters are used beyond replacement time, they may impede airflow decreasing A/C and heating performance. Make sure these filters are part of your recommended service. Note that some of our vehicles may not have been factory equipped but will accept the filters as an accessory. - Express the value in maintaining the finish quality of the customer's vehicle at the Maintenance I and II visits. More fully utilize the vehicle prep personnel you already have in place. In today's world, many people simply ignore the finish of their vehicle, at best infrequently using an automatic car wash for exterior cleaning. Offer vehicle detailing services in stages from just a wash and wax to a complete interior cleaning. When paired with the Simplified Maintenance visit, this will increase customer satisfaction. On return, the customer gets a visibly improved vehicle that will be a source of pride of ownership along with a vehicle that is now fully maintained. Also, reinforce the improved resale value of a completely maintained vehicle. - For customers who clean and maintain the appearance of their vehicles themselves encourage the use of GM Vehicle Care products. Many customers may have never used GM Car Wash/Wax Concentrate, GM Cleaner Wax or a longtime product, GM Glass Cleaner, which is a favorite of many customers who try it just once. If your dealership give samples of these products with new car purchases, customers may already be sold on the product but not willing to make a special trip to the dealership. Capitalize on sales at this time. Stock shelves right at the Service counter with these products and consider instituting compensation programs for Service Consultants who suggest these products. Many consumers faced with an intimidating wall full of car care products sold at local auto parts stores may find it comforting to purchase a fully tested product sold by GM that they know will not harm the finish of their vehicle. We suggest these competitively priced basic vehicle care products to emphasize: In USA: - #12378401 GM Vehicle Care Wash/Wax Concentrate 16 fl. oz. (0.473L) - #89021822 GM Vehicle Care Glass Cleaner Aerosol 18 oz. (510 g) - #12377966 GM Vehicle Care Cleaner Wax 16 fl. oz. (0.473L) - #1052929 GM Vehicle Care Chrome and Wire Wheel Cleaner 16 fl. oz. (0.473L) - #88861431 GM Vehicle Care Odor Eliminator 24 fl. oz. (0.710L) In Canada: - #10953203 GM Vehicle Care Wash & Wax Concentrate 473 mL - #992727 GM Glass Cleaner Aerosol 500 g - #10952905 GM Vehicle Care Liquid Cleaner/Wax 473 mL - #10953013 GM Vehicle Care Chrome Cleaner and Polish 454 mL - #10953202 GM Vehicle Care Wheel Brite 473 mL - #88901678 GM Vehicle Care Odor Eliminator 473 mL - Display signboards with the installed price for popular GM Accessories such as running boards and Tonneau Covers. Customers may not think to ask about these desirable items at the time of a service visit. - Finally, take advantage of the GM Goodwrench initiatives (Tire Program, Goodwrench Credit Card, etc. / Dealer Marketing Association (DMA) Promotions in Canada) to provide the customer with more reasons to identify your dealership as the best place to go for parts and service. Remember to utilize ALL of the service aspects you possess in your dealership to satisfy and provide value to your customer. Many businesses exist profitably as an oil change location, a vehicle repair facility, or a detailing shop alone. You already have the capabilities of all three and provide these services with the inherent trust of your customer, under the GM Mark of Excellence. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair Actuator: Service and Repair Front Drive Axle Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Disconnect the electrical connector from the actuator. 4. Remove the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.5 inch axle (4) by turning the actuator counterclockwise. Installation Procedure 1. Apply sealant to the threads of the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.25 inch axle (4). Use the correct sealant. Refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 7667 Adhesives, Fluids, Lubricants, and Sealers (See: Fluid - Differential/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the actuator (1 or 3). Tighten the actuator to 20 Nm (15 lb ft). 3. Connect the electrical connector to the actuator. 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Drivetrain - Front Axle Vent Hose Routing Differential Case: Technical Service Bulletins Drivetrain - Front Axle Vent Hose Routing INFORMATION Bulletin No.: 08-04-19-004A Date: January 06, 2010 Subject: Correct Front Axle Vent Hose Routing Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL with Four Wheel Drive or All Wheel Drive Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 08-04-19-004 (Section 04 - Driveline/Axle). The front axle vent hose is mounted in the left side of the engine compartment, and may not be correctly routed. The vent hose can get misrouted and placed in a position that is lower than the front axle harness/engine harness in-line connector. In this position, the vent tube may ingest water. The front axle vent hose may be routed to the wheel side of the wheel well. It may be hanging through the opening of the wheel well in a vertical position, with the vent cap hanging down. If you encounter a vehicle with the front axle vent hose misrouted, reroute the hose to the correct location. The hose should be mounted inside the engine compartment, in an upward position to prevent the possibility of water being drawn into the hose and axle assembly during cool-down. Tape the vent hose to the nearby wiring harness as shown. Technicians should also change the front axle fluid. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Drivetrain - Front Axle Vent Hose Routing > Page 7672 For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) Differential Clutch: Service and Repair Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) 1. Remove the guide clips (3). 2. Remove the clutch discs and the splined discs (2, 4-6) from the locking differential side gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) > Page 7677 Differential Clutch: Service and Repair Locking Differential Clutch Disc Assembly Disassemble (9.5 Inch Axle) Locking Differential Clutch Disc Assembly Disassemble (9.5 Inch Axle) 1. Remove the guide clips (2). 2. Remove the clutch discs and the splined discs (3-7) from the locking differential side gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) > Page 7678 Differential Clutch: Service and Repair Locking Differential Clutch Disc Assembly Disassemble (10.5 Inch Axle) Locking Differential Clutch Disc Assembly Disassemble (10.5 Inch Axle) 1. Remove the guide clips (6). 2. Remove the clutch discs and the splined discs (2-5, 7) from the locking differential side gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) > Page 7679 Differential Clutch: Service and Repair Locking Differential Clutch Disc Assembly Disassemble (11.5 Inch Axle) Locking Differential Clutch Disc Assembly Disassemble (11.5 Inch Axle) 1. Remove the guide clips (3). 2. Remove the clutch discs and the splined discs (2, 4-7) from the side gear (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) > Page 7680 Differential Clutch: Service and Repair Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) 1. Remove the guide clips (3). 2. Remove the clutch discs and the splined discs (2, 4-6) from the locking differential side gear (1). Locking Differential Clutch Disc Assembly Disassemble (9.5 Inch Axle) Locking Differential Clutch Disc Assembly Disassemble (9.5 Inch Axle) 1. Remove the guide clips (2). 2. Remove the clutch discs and the splined discs (3-7) from the locking differential side gear (1). Locking Differential Clutch Disc Assembly Disassemble (10.5 Inch Axle) Locking Differential Clutch Disc Assembly Disassemble (10.5 Inch Axle) 1. Remove the guide clips (6). 2. Remove the clutch discs and the splined discs (2-5, 7) from the locking differential side gear (1). Locking Differential Clutch Disc Assembly Disassemble (11.5 Inch Axle) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) > Page 7681 Locking Differential Clutch Disc Assembly Disassemble (11.5 Inch Axle) 1. Remove the guide clips (3). 2. Remove the clutch discs and the splined discs (2, 4-7) from the side gear (1). Locking Differential Clutch Disc Assembly Assemble (8.6 Inch Axle) Locking Differential Clutch Disc Assembly Assemble (8.6 Inch Axle) 1. Apply the correct axle lubricant to the surface of each disc. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid Differential/Specifications/Fluid Type Specifications). 2. Assemble the right side or bell-end side clutch disc assembly as follows: 1. Install the two-sided carbon eared disc (2) to the side gear (1). 2. Install the 1st splined disc (4). 3. Install the 2nd splined disc (5). 4. Install the one-sided carbon eared disc (6). 5. Install the guide clips (3) to the clutch discs (2, 4-6). Apply chassis grease to the guide clips in order to hold the clips in place on the disc ears. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid - Differential/Specifications/Fluid Type Specifications). Locking Differential Clutch Disc Assembly Assemble (9.5LD Axle) Locking Differential Clutch Disc Assembly Assemble (9.5LD Axle) 1. Apply proper axle lubricant to the surface of each disc. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid - Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) > Page 7682 Differential/Specifications/Fluid Type Specifications). 2. Assemble the right side or bell-end side clutch disc assembly as follows: 1. Install the 1st non-carbon eared disc (3) to the side gear (1). 2. Install the 1st splined disc (4). 3. Install the 2nd non-carbon eared disc (5). 4. Install the 2nd splined disc (6). 5. Install the 3rd non-carbon eared disc (7). 6. Install the guide clips (2) to the clutch discs (2-7). Apply chassis grease to the guide clips in order to hold the clips in place on the disc ears. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid - Differential/Specifications/Fluid Type Specifications). Locking Differential Clutch Disc Assembly Assemble (10.5) Locking Differential Clutch Disc Assembly Assemble (10.5) 1. Apply the proper axle lubricant to the surface of each disc. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid Differential/Specifications/Fluid Type Specifications). 2. Assemble the left side clutch disc assembly as follows: 1. Install the 1st non-carbon eared disc (2) to the side gear (1). 2. Install the 1st splined disc (3). 3. Install the 2nd non-carbon eared disc (4). 4. Install the 2nd splined disc (5). 5. Install the 3rd non-carbon eared disc (7). 6. Align the ears of all the clutch discs. 7. Install the guide clips (6) to the clutch discs (2-5, 7). Apply the proper chassis grease to the guide clips in order to hold the clips in place on the disc ears. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid Differential/Specifications/Fluid Type Specifications). Locking Differential Clutch Disc Assembly Assemble (11.5 Inch Axle) Locking Differential Clutch Disc Assembly Assemble (11.5 Inch Axle) 1. Apply axle lubricant, GM P/N 12378261 (Canadian P/N 10953455) or equivalent meeting GM Specification 9986115, to the surface of each disc. 2. Assemble the right side or bell-end side clutch disc assembly as follows: 1. Install the 1st eared disc (2) to the side gear (1). 2. Install the 1st carbon splined disc (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) > Page 7683 3. Install the 2nd eared disc (5). 4. Install the 2nd carbon splined disc (6). 5. Install the 3rd eared disc (7). 6. Install the guide clips (3) to the clutch discs (2, 4-7). Apply grease to the guide clips in order to hold the clips in place on the disc ears. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair Actuator: Service and Repair Front Drive Axle Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Disconnect the electrical connector from the actuator. 4. Remove the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.5 inch axle (4) by turning the actuator counterclockwise. Installation Procedure 1. Apply sealant to the threads of the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.25 inch axle (4). Use the correct sealant. Refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair > Page 7688 Adhesives, Fluids, Lubricants, and Sealers (See: Fluid - Differential/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the actuator (1 or 3). Tighten the actuator to 20 Nm (15 lb ft). 3. Connect the electrical connector to the actuator. 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications DRIVE AXLE FLUID CAPACITIES FRONT AXLE 1000 Series (8.25") ...................................................................................................... ..................................................................... 1.43 liters (1.51 quarts) 2000 Series (9.25") .................. ......................................................................................................................................................... 1.73 liters (1.83 quarts) REAR AXLE 1000 Series without RPO AXN (8.6") .............................................................................................................................................. 2.03 liters (2.15 quarts) 1000 Series with RPO AXN (9.5"LD) ................................................................................................................................................ 2.6 liters (2.75 quarts) 2000 Series (9.5"HD) ............................................................................................ ............................................................................. 2.6 liters (2.75 quarts) 2000 Series with RPO LY6 (10.5") .................................................................................................................................................... 2.6 liters (2.75 quarts) 2000 Series with RPO LMM (11.5") .................................................................................................................................................. 3.0 liters (3.17 quarts) 3000 Series (11.5") ................................................................................................ ............................................................................. 3.0 liters (3.17 quarts) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 7693 Fluid - Differential: Fluid Type Specifications FRONT AXLE (1500 SERIES) SAE 80W-90 Axle Lubricant (GM Part No. U.S. 89021671, in Canada 89021672). FRONT AXLE (1500 HD, 2500 HD, and 3500 HD SERIES) SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. REAR AXLE SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures Fluid - Differential: Procedures Front Drive Axle Front Axle Lubricant Level Inspection (9.25 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Clean the area around the front axle fill plug. 5. Remove the front axle fill plug (1). 6. Inspect the oil level. The 9.25 inch axle the oil level should be between 0-6 mm (0-0.25 in) below the fill plug opening. 7. If the level is low, add oil until the level is between 0-6 mm (0-0.25 in) for the 9.25 inch axle. Use the correct fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) Note: All axle assemblies are filled by volume of fluid during production. They are not filled to reach a certain level. When checking the fluid level on any axle, variations in the readings can be caused by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle has just been driven before checking the fluid level, it may appear lower than normal because the fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level than a vehicle that has been stationary for an hour or two. Remember that the rear axle assembly must be supported to get a true reading. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Ensure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 7696 5. Remove the rear axle fill plug. 6. Inspect the lubricant level: The lubricant level should be between 1-19 mm (0.04-0.75 in) below the fill plug opening for the 8.6 inch axle. The lubricant level should be between 15-40 mm (0.59-1.57 in) below the fill plug opening for the 9.5 inch LD axle. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (11.5 Inch Axle) Rear Axle Lubricant Level Inspection (11.5 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 7697 The lubricant level should be between 17-21 mm (0.6-0.8 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is between 17-21 mm (0.6-0.8 in) below the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug and gasket. Tighten the rear axle fill plug to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (10.5 Inch Axle) Rear Axle Lubricant Level Inspection (10.5 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 lb ft). 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 7698 Fluid - Differential: Removal and Replacement Front Drive Axle Front Axle Lubricant Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Clean the area around the front axle fill plug and the drain plug. 4. Remove the fill plug. 5. Remove the drain plug. 6. Drain the fluid from the front differential carrier assembly. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the drain plug. Tighten the drain plug to 33 Nm (24 lb ft). 2. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Approximate Fluid Capacities (See: Maintenance/Specifications) and Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). 3. Install the fill plug. Tighten the fill plug to 33 Nm (24 lb ft). 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 5. Lower the vehicle. Differential Oil Replacement (8.6 Inch Axle) Differential Oil Replacement (8.6 Inch Axle) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 7699 Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Clean the area around the rear axle fill plug. 3. Remove the rear axle fill plug. 4. Remove the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 5. Drain the lubricant into a suitable container. Installation Procedure 1. Install the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 2. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities (See: Maintenance/Specifications) and Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 4. Lower the vehicle. Differential Oil Replacement (9.5LD Inch Axle) Differential Oil Replacement (9.5LD Inch Axle) Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 7700 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the drain plug. 3. Remove the fill plug. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the drain plug and tighten to 33 Nm (24 lb ft). 2. Fill the rear drive axle. * Use the proper fluid, refer to Approximate Fluid Capacities (See: Maintenance/Specifications). * For the proper capacity, refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 7701 3. Install the fill plug and tighten to 33 Nm (24 lb ft). 4. Remove the support and lower the vehicle. Differential Oil Replacement (10.5 Inch Axle) Differential Oil Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the fill plug (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 7702 3. Remove the rear axle drain plug (1). 4. Drain the lubricant into a suitable container. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the rear axle drain plug (1) and tighten to 33 Nm (24 lb ft). 2. Fill the rear axle with the proper fluid. Refer to Approximate Fluid Capacities (See: Maintenance/Specifications) and Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 7703 3. Install the fill plug (1) and tighten to 33 Nm (24 lb ft). 4. Remove the support and lower the vehicle. Differential Oil Replacement (11.5 Inch Axle) Differential Oil Replacement (11.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) in General Information. 2. Remove the fill plug. 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 7704 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the rear axle drain plug and tighten to 33 Nm (24 lb ft). 2. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities (See: Maintenance/Specifications) and Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance) in Maintenance and Lubrication. 3. Install the fill plug and washer and tighten to 33 Nm (24 lb ft). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments Differential Output Shaft Bearing: Adjustments Inner Axle Shaft Shim Adjustment Special Tools * J 34672 Depth Micrometer * J 34673 Flat Gauge Bar * J 8001 Dial Indicator Set The front drive axle clutch gear shim needs to be measured and adjusted if any of the following parts are replaced: * The inner axle shaft * The inner axle shaft housing * The clutch shaft * The differential carrier case * The ring and pinion gears * The differential assembly * The differential bearings * The carrier connector Front drive axle clutch shims are available in the following sizes: 1. Install the inner axle bearing and the inner axle seal, if necessary. Refer to Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 7709 2. Install the following components into the inner axle shaft housing: 1. Install the inner axle shaft (1) into the inner axle shaft housing (4). 2. Install the thrust washer (with tabs) (5). Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing. 3. Install the thrust washer (without tabs) (6). 4. Install the retaining ring (7) into the inner axle shaft (1). 3. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. Note: In order to obtain an accurate measurement, the inner axle shaft must be moved outwards before measuring. 4. Push on the inner end of the inner axle shaft and move the shaft outboard as far as it will go. 5. Install the J 34673 (1) and the J 34672 (2) onto the inner shaft housing as shown. 6. Using the J 34672 , measure the distance from the edge of the inner axle shaft to the surface of the J 34673 . Ensure the base of the J 34672 is flat against the inner axle shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 7710 7. Using the J 34672 , measure the distance from the machined surface of the differential carrier housing to the outer surface of the front drive axle clutch shaft. 8. Subtract the measurement obtained in step 6 from the measurement obtained in step 7. This measurement is the distance between the inner axle shaft and the clutch shaft before subtracting the J 34673 . 9. Using a micrometer, measure the thickness of the J 34673 . 10. Subtract the thickness of the J 34673 , measured in step 9, from the measurement determined in step 8. This is the shim thickness for the front axle without having any axle shaft endplay. 11. The correct shim size will be one size smaller than the figure obtained in the previous step. Note the following examples: * If the figure obtained in step 8 was 3.53 mm (0.139 in), use a 3.30 mm (0.130 in) shim. * If the figure obtained in step 8 was 3.30 mm (0.130 in), use a 3.05 mm (0.120 in) shim. Alternate Adjustment Method Note: Use this method only if the proper tools for calculating the shim size are unavailable. 1. Install the original shim to the shaft. Use the chassis grease in order to hold the shim in place. 2. Install the inner axle housing assembly to the differential carrier case. Do not use sealer at this time. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolts and tighten to 40 Nm (30 lb ft). 4. Measure the shaft end play using the following procedure: 1. Install the J 8001 or the equivalent on the axle tube end. The plunger of the indicator must be at a right angle to the axle flange. 2. Move the shaft back and forth and read the end play. The correct end play is 0.03-0.51 mm (0.001-0.020 in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 7711 3. If the end play is incorrect, install a thicker or thinner shim as needed in order to bring the end play into the specified range. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 7712 Differential Output Shaft Bearing: Service and Repair Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement Special Tools * J 8092 Universal Driver Handle - 3/4 in - 10 * J 2619-01 Slide Hammer * J 29369-1 Bushing and Bearing Remover * J 29369-2 Bushing and Bearing Remover (2-3 inch) * J 36609 Axle Tube Bearing Installer * J 45225 Axle Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Drain the differential carrier assembly. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement). 3. Remove the right side seal and/or bearing by performing the following steps: 1. Remove the inner axle shaft and housing assembly from the differential carrier case assembly. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). 2. Remove the clutch fork assembly components and the inner axle shaft from the inner axle shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). 3. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. 4. Install the J 29369-1 , 8.25 inch axle, or the J 29369-2 , 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary. 5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 (1). 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01 . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 7713 Note: Support the wheel drive shaft in order to not over flex the CV joint. 4. If only replacing the left side seal, perform the following steps: 1. Place an alignment mark between the inner axle shaft and the wheel drive shaft. 2. If servicing the 8.25 inch axle, remove the shock module. Refer to Shock Absorber and Spring Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Shock Absorber/Shock Absorber and Spring Assembly Replacement). 3. Disconnect the wheel drive shaft from the inner axle shaft. 4. Remove the inner axle shaft using a hammer and a brass drift. 5. Remove the inner axle shaft seal using a suitable seal remover tool. 5. If replacing both the left side seal and bearing, perform the following steps: 1. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Service and Repair )Differential Carrier Assembly Replacement (2500 4WD) (See: Service and Repair). 2. Place the differential carrier assembly into a vise. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 7714 Clamp only on the mounting flange of the differential carrier assembly case. 3. Remove the inner axle shaft using a hammer and a brass drift. 4. Install the J 29369-1 , 8.25 inch axle, or the J 29369-2 , 9.25 inch axle (1), behind the inner axle shaft seal or the inner axle shaft bearing as necessary. 5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 . 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01 . Installation Procedure 1. Install the right side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). 2. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 3. Install the inner axle shaft into the inner axle shaft housing. Carefully tap the inner axle shaft into place with a soft-faced mallet. 4. Install the inner axle shaft and clutch fork assembly components into the inner shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). 5. Install the inner axle shaft and housing assembly to the differential carrier case assembly. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 7715 6. If both the left side bearing and seal was removed, perform the following step. Install the left side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). 7. If both the left side bearing and seal was removed, perform the following step. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 8. If both the left side bearing and seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 9. If both the left side bearing and seal was removed, perform the following step. Install the front differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Service and Repair)Differential Carrier Assembly Replacement (2500 4WD) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 7716 10. If only the left side seal was removed, perform the following step. Install the seal using the J 45225 and a soft-faced mallet. Tap only on the center portion of the J 45225 in order to drive the seal in evenly. 11. If only the left side seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 12. If servicing the 8.25 inch axle, install the shock module. Refer to Shock Absorber and Spring Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Shock Absorber/Shock Absorber and Spring Assembly Replacement). 13. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 14. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft bolts and tighten to 79 Nm (58 lb ft). 15. Fill the differential carrier assembly. Use the correct fluid. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 7717 16. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) Pinion Bearing: Service and Repair Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) Special Tools * DT 47688 - Pinion Bearing Remover * J 7818 - Inner Bearing race Installer * J 8092 - Universal Driver Handle 3/4-10 * J 8611-01 - Pinion Bearing Cup Installer * J 8614-01 - Flange Holder and Remover * J 22306 - Bearing Race Installer * J 22828 - Input Shaft Gear Installer * J 22912 - Bearing Remover * J 36614 - Inner Pinion Bearing Installer * J 45870 - Inner Pinion Bearing Race Installer Disassemble Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 3. Remove the drive pinion from the axle. Refer to Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5 LD, and 11.5 Inch Axles) ()Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) (See: Pinion Gear/Service and Repair/Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)). Note: Step 4 is for those vehicles equipped with the 8.6 inch axle. 4. Using the DT 47688 - remover and a press, remove the bearing from the drive pinion. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 7722 Note: Step 5 is for those vehicles equipped with the 9.5 LD inch axle. 5. Using the J 22912 - remover and a press, remove the differential pinion bearing. 6. Remove the shim (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 7723 Note: Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. 7. Using a hammer and a brass drift in the slots provided, remove the outer pinion bearing cup from the axle housing. Note: Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. 8. Using a hammer and a brass drift in the slots provided, remove the inner pinion bearing cup from the axle housing. Assemble Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 7724 1. Using the J 8611-01 - installer , 8.6 inch axle, or the J 7818 - installer , 9.5/9.5LD inch axle (1), and the J 8092 (2), install the outer pinion bearing cup. 2. Using the J 45870 , 8.6 inch axle, or the J 22306 , 9.5/9.5LD inch axle (2), and the J 8092 (1), install the inner pinion bearing cup. 3. Determine the selective shim thickness for the drive pinion. Refer to Pinion Depth Adjustment (8.6, 9.5/9.5 LD and 11.5 Inch Axles) ()Pinion Depth Adjustment (10.5 Inch Axle) (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 7725 4. Install the selective shim (1) on the shoulder on the differential pinion gear (2). Note: Press the bearing on until the cone seats on the pinion shim. 5. Using the J 22828 - installer or the J 36614 - installer , install the inner pinion bearing. 6. Install a new collapsible spacer. 7. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). 8. Install the outer pinion bearing into the axle housing. 9. Install the differential pinion gear into the axle housing. Note: DO NOT re-use the old pinion nut, replace with NEW only. 10. Install the NEW differential pinion oil seal, flange/yoke, and the NEW nut and washer. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 7726 11. Using an inch-pound torque wrench, measure the rotating torque of the pinion should be between 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings. 12. If the rotating torque measurement is below 1.0 Nm (10 lb in) for used bearings, or 1.7 Nm (15 lb in) for new bearings, continue to tighten the pinion nut in small increments, until the torque required in order to rotate the pinion is between 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings. 13. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. 14. Recheck the rotating torque of the pinion bearing and adjust if necessary. 15. Install the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 16. Fill the axle with lubricant. Use the proper fluid. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 17. Remove the support and lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 7727 Pinion Bearing: Service and Repair Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle) Special Tools * J 8092 - Universal Driver Handle - 3/4 in - 10 * J 8608 - Pinion Bearing Cup Installer * J 8614-01 - Flange Holder and Remover * J 22761 - Side Bearing Installer * J 22912-B - Bearing Remove * J 24433 - Pinion Bearing Installer * J 37624 - Pinion Bearing Installer * J 44414 - Pinion Oil Seal Installer For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Rear Drive Axle). Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 3. Remove the pinion gear bearing retainer. Refer to Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) (See: Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle))Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle) . 4. Remove the pinion yoke and the oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). 5. Remove the outer pinion bearing. 6. Using an hydraulic press and the appropriate supports, remove the differential pinion gear. 7. Remove the collapsible spacer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 7728 8. Using the J 22912-B - remover and a hydraulic press, remove the inner pinion bearing from the differential pinion gear. Note: * Insert the brass drift in the slots to remove the bearing cup. * Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 9. Using a hammer and a brass drift, remove the outer pinion bearing cup. Note: * Insert the brass drift in the slots to remove the bearing cup. * Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 10. Using a hammer and a brass drift, remove the inner pinion bearing cup. 11. Using a brass drift and a hammer, remove the pinion gear pilot bearing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 7729 Installation Procedure 1. Position the drive pinion pilot gear bearing (1) in the differential housing. 2. Using the J 22761 - installer (1) and the J 8092 - driver (2), install the drive pinion gear pilot bearing in the differential housing (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 7730 3. Using the J 37624 - installer (2) and the J 8092 - driver (1), install the inner pinion bearing cup in the pinion gear bearing retainer. 4. Using the J 8608 - installer (2) and the J 8092 - driver (1), install the outer pinion bearing cup in the pinion gear bearing retainer. Note: Press the bearing on until the cone seats on the pinion. 5. Using the J 24433 - installer and a hydraulic press, install the inner pinion bearing. 6. Install the new collapsible spacer. 7. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). 8. Install the outer pinion bearing into the pinion bearing retainer. 9. Using the J 44414 - installer , install the new pinion oil seal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 7731 10. Install the pinion in the pinion gear bearing retainer. 11. Install the drive pinion flange/yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). Note: Do not apply sealant to the pinion gear bearing retainer at this time. 12. Install the original shim to the pinion bearing retainer. If the original shim is not available, install a 0.41 mm (0.016 in) shim to build pinion depth. 13. Install the pinion gear bearing retainer to the axle housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 14. Install the pinion bearing retainer bolts and tighten to 88 Nm (65 lb ft). 15. Using an inch-pound torque wrench, measure the rotational torque of the pinion it should be between 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings. 16. If the rotating torque measurement is below 1.0 Nm (10 lb in) for used bearings, or 1.7 Nm (15 lb in) for new bearings, use the J 8614-01 remover and continue to tighten the pinion nut in small increments until the rotational torque is between 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings. 17. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 18. Install the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 19. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment (8.6 Inch Axle) ()Differential Carrier Bearing Preload Adjustment (10.5/11.5 Inch Axles) (). 20. Determine the selective shim thickness for the drive pinion. Refer to Pinion Depth Adjustment (8.6, 9.5/9.5 LD and 11.5 Inch Axles) ()Pinion Depth Adjustment (10.5 Inch Axle) (). 21. Adjust the backlash. Refer to Backlash Adjustment (8.6 Inch Axle) ()Backlash Adjustment (10.5/11.5 Inch Axle) ()Backlash Adjustment (9.5 LD Axle) (). 22. Fill the axle with lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 23. Remove the support and lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle Pinion Flange: Service and Repair Front Drive Axle Front Differential Drive Pinion Gear Yoke Replacement Special Tools * J 8614-01 Flange and Pulley Holding Tool * J 36366 Pinion Oil Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Drain the drive axle. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement). 3. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 4. Remove the brake calipers. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)). 5. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 6. Reference mark the relationship of the propeller shaft to the front axle pinon yoke. 7. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 8. Disconnect the propeller shaft universal joint (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. 9. Support the propeller shaft and move out of the way as necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7736 10. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components: * The pinion bearings * The pinion seal * The carrier bearings * The axle bearings * The axle seals 11. Scribe an alignment line between the pinion shaft and the pinion yoke. 12. Install the J 8614-01 onto the pinion as shown. 13. Remove the pinion nut while holding the J 8614-01 . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7737 14. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 15. Remove the pinon yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Note: Carefully remove the oil seal from the bore. Do not distort or scratch the aluminum case. 16. Remove the oil seal using a suitable seal removal tool. Installation Procedure 1. Install the oil seal by doing the following: 1. Position the oil seal over the seal bore. 2. Install the J 36366 over the oil seal. 3. Strike the J 36366 with a hammer until the seal flange seats on the axle housing surface. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke. 3. Install the pinion yoke. Align the reference marks made during removal. Caution: Refer to Pinion Flange/Yoke Installation Caution (See: Service Precautions/Vehicle Damage Warnings/Pinion Flange/Yoke Installation Caution). 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7738 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 7. Tighten the pinion nut while holding the J 8614-01 . Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 8. Measure the rotating torque of the pinion using an inch-pound torque wrench. Compare the measurement with the rotating torque recorded earlier. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 Nm (3-5 lb in) greater than the torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft universal joint (2) to the pinion yoke (1). Align the reference marks made during removal. 11. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 12. Inspect the axle lubricant level, and add, if necessary. Refer to Front Axle Lubricant Level Inspection (9.25 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Front Drive Axle). 13. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 14. Install the brake calipers. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)). 15. Fill the drive axle. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement). 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 17. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7739 Pinion Flange: Service and Repair Rear Drive Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement Special Tools * J 8614-01 - Flange Holder and Remover * J 22388 - Pinion Oil Seal Installer * J 44414 - Pinion Oil Seal Installer Removal Procedure Note: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Remove the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 4. Remove the rear disc brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). Note: The following procedure is for the 10.5 or 11.5 inch axles. 5. Remove the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). Note: Reference mark the rear propeller shaft to the rear axle pinion yoke. 6. Remove the propeller shaft. * For vehicles equipped the a one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with a two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). Note: Record this measurement for reassembly. 7. Using an inch-pound torque wrench, measure the rotational torque of the differential ring and pinion gear and related components. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7740 8. Place an alignment mark between the pinion and the pinion yoke. Note: * DO NOT reuse the pinion nut, replace with NEW. * For the 11.5 inch axle, use J-34826 socket. 9. Using the J 8614-01 - holder and remover or the J-34826 socket, remove and discard the pinion the pinion nut. Note: Remove the pinion yoke by turning the J 8614-3 (3) clockwise. 10. Using the J 8614-2 (2), J 8614-3 (3) and the J 8614-01 - remover (1), remove the pinion yoke. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7741 Note: DO NOT damage the axle housing. 11. Using a suitable tool, remove the pinion oil seal. Installation Procedure 1. Using the J 22388 - installer , install the new pinion oil seal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7742 2. Apply the proper sealant to the splines of the pinion yoke. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid Differential/Specifications/Fluid Type Specifications). 3. Align the reference marks and install the pinion yoke. Caution: Refer to Pinion Flange/Yoke Installation Caution (See: Service Precautions/Vehicle Damage Warnings/Pinion Flange/Yoke Installation Caution). Note: Tap the pinion yoke until a few threads show through the pinion yoke. 4. Using a soft faced hammer, seat the pinion yoke onto the pinion shaft. 5. Install the washer and a NEW pinion nut. Note: * If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. * For the 11.5 inch axle, use J-34826 socket. 6. Holding the J 8614-01 - holder or the J-34826 socket, tighten the pinion nut until the pinion end play is just taken up. 7. Rotate the pinion while tightening the nut to seat the bearings. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7743 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Compare this measurement with the rotating torque recorded during removal. 8. Using an inch pound torque wrench and tightening in small increments, measure the rotating torque of the pinion until the reading is greater than 0.40-0.57 Nm (3-5 lb in) , the rotational torque noted at removal. Note: Recheck the rotating torque and adjust if necessary. 9. Once the specified torque is obtained, rotate the pinion several times to seat the bearings. Note: Reference mark the rear propeller shaft to the rear axle pinion yoke. 10. Install the propeller shaft. * For vehicles equipped the a one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with a two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). Note: The following procedure is for the 10.5 or 11.5 inch axles. 11. Install the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). 12. Install the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 13. Install the rear disc brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 14. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 15. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)). 16. Remove the support and lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7744 Pinion Flange: Service and Repair Allison - Automatic Transmission Differential Drive Pinion Gear Yoke Replacement Removal Procedure 1. Place the transmission in the Park (P) selector position. Warning Apply the parking brake and block the drive wheels before performing this procedure in order to prevent bodily injury. 2. Apply the parking brake and chock the wheels to prevent vehicle movement. 3. Remove the vehicle driveline from the transmission yoke assembly (1). Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair). Remove the bolt (3) and seal-ring washer (2). 4. Remove the yoke assembly (1). Note: Do the following prior to installation of the yoke assembly: * Be sure the yoke, output shaft and retaining hardware are clean. * Verify the output seal is free of tears or cuts. * DO NOT attempt to remove scratches from the output seal journal on the yoke assembly. Repair may produce machine lead and leakage. 5. Inspect the yoke assembly and replace it whenever there are nicks or scratches on the seal journal or on the lead-in chamfer just ahead of the seal journal. Installation Procedure 1. Lubricate the internal splines and the rear seal journal of the yoke assembly with clean transmission fluid. 2. Install the yoke assembly (1) onto the transmission output shaft. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolt (3) and seal-ring washer (2). Tighten the bolt to 123 Nm (91 lb ft). 4. Attach the vehicle driveline to the transmission yoke assembly. Refer to Transmission Replacement (See: Automatic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7745 Transmission/Transaxle/Service and Repair). 5. Be sure the selector is in the Park (P) position. 6. Remove the wheel chocks before continuing operation of the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement Pinion Gear: Service and Repair Drive Pinion Housing and/or Seal Replacement Drive Pinion Housing and/or Seal Replacement Special Tools * J 8092 - Universal Driver Handle 3/4 x 10 inch * J 8608 - Pinion bearing Cup Installer * J 24433 - Pinion Bearing Installer * J 37624 - Pinion Bearing Installer * J 44414 - Pinion Oil Seal Installer Removal Procedure Note: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Drain the axle lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 3. Remove the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). 4. Remove the rear propeller shaft. * For vehicles equipped with the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with the two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 5. Remove the drive pinion flange/yoke and/or oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). 6. Using a hydraulic press and an appropriate tool, remove the pinion. 7. Remove the collapsible spacer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 7750 Note: When performing the following service procedure, move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 8. Using a hammer and a brass drift in the slots provided, remove the outer pinion bearing cup. Note: When performing the following service procedure, move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 9. Using a hammer and a brass drift in the slots provided, remove the inner pinion bearing cup. Installation Procedure 1. Using the J 37624 (2) and the J 8092 (1), Install the inner pinion bearing cup into the pinion gear bearing retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 7751 2. Using the J 8608 (2) and the J 8092 (1), install the outer pinion bearing cup into the pinion gear bearing retainer. 3. Apply sealant to surface of the selective shim. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid - Differential/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the pinion gear bearing retainer and bolts tighten to 88 Nm (65 lb ft). 5. Install the drive pinion flange/yoke and/or oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). 6. Install the propeller shaft. * For vehicles equipped with the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with the two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 7. Install the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). 8. Fill the axle with axle lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement )Differential Oil Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 9. Remove the support and lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 7752 Pinion Gear: Service and Repair Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the differential case assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 3. Remove the drive pinion housing assembly. Refer to Drive Pinion Housing and/or Seal Replacement (See: Drive Pinion Housing and/or Seal Replacement). 4. Remove and discard the gear bolts. Replace with NEW only. Caution: Refer to Ring Gear Removal Caution (See: Service Precautions/Vehicle Damage Warnings/Ring Gear Removal Caution). 5. Using a brass drift and a hammer, remove the ring gear from the differential case. Installation Procedure 1. If the differential case has become separated, assemble the differential case by aligning the two arrows inside the differential case. Note: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 2. Install the ring gear to the differential case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 7753 Note: Use hand tools ONLY. DO NOT use power tools for the following procedure. 3. Hand tighten the new ring gear bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the NEW ring gear bolts and tighten to 165 Nm (122 lb ft). in a criss cross pattern to draw and seat the ring gear and the on the differential case. 5. Install the drive pinion housing assembly. Refer to Drive Pinion Housing and/or Seal Replacement (See: Drive Pinion Housing and/or Seal Replacement). 6. Install the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 7. Fill the axle with the proper lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 8. Remove the support and lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair Ring Gear: Service and Repair Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the differential case assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 3. Remove the drive pinion housing assembly. Refer to Drive Pinion Housing and/or Seal Replacement (See: Pinion Gear/Service and Repair/Drive Pinion Housing and/or Seal Replacement). 4. Remove and discard the gear bolts. Replace with NEW only. Caution: Refer to Ring Gear Removal Caution (See: Service Precautions/Vehicle Damage Warnings/Ring Gear Removal Caution). 5. Using a brass drift and a hammer, remove the ring gear from the differential case. Installation Procedure 1. If the differential case has become separated, assemble the differential case by aligning the two arrows inside the differential case. Note: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 2. Install the ring gear to the differential case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Page 7757 Note: Use hand tools ONLY. DO NOT use power tools for the following procedure. 3. Hand tighten the new ring gear bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the NEW ring gear bolts and tighten to 165 Nm (122 lb ft). in a criss cross pattern to draw and seat the ring gear and the on the differential case. 5. Install the drive pinion housing assembly. Refer to Drive Pinion Housing and/or Seal Replacement (See: Pinion Gear/Service and Repair/Drive Pinion Housing and/or Seal Replacement). 6. Install the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 7. Fill the axle with the proper lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 8. Remove the support and lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle Seals and Gaskets: Service and Repair Front Drive Axle Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement Special Tools * J 8092 Universal Driver Handle - 3/4 in - 10 * J 2619-01 Slide Hammer * J 29369-1 Bushing and Bearing Remover * J 29369-2 Bushing and Bearing Remover (2-3 inch) * J 36609 Axle Tube Bearing Installer * J 45225 Axle Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Drain the differential carrier assembly. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement). 3. Remove the right side seal and/or bearing by performing the following steps: 1. Remove the inner axle shaft and housing assembly from the differential carrier case assembly. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). 2. Remove the clutch fork assembly components and the inner axle shaft from the inner axle shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). 3. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. 4. Install the J 29369-1 , 8.25 inch axle, or the J 29369-2 , 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary. 5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 (1). 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01 . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7762 Note: Support the wheel drive shaft in order to not over flex the CV joint. 4. If only replacing the left side seal, perform the following steps: 1. Place an alignment mark between the inner axle shaft and the wheel drive shaft. 2. If servicing the 8.25 inch axle, remove the shock module. Refer to Shock Absorber and Spring Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Shock Absorber/Shock Absorber and Spring Assembly Replacement). 3. Disconnect the wheel drive shaft from the inner axle shaft. 4. Remove the inner axle shaft using a hammer and a brass drift. 5. Remove the inner axle shaft seal using a suitable seal remover tool. 5. If replacing both the left side seal and bearing, perform the following steps: 1. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Service and Repair )Differential Carrier Assembly Replacement (2500 4WD) (See: Service and Repair). 2. Place the differential carrier assembly into a vise. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7763 Clamp only on the mounting flange of the differential carrier assembly case. 3. Remove the inner axle shaft using a hammer and a brass drift. 4. Install the J 29369-1 , 8.25 inch axle, or the J 29369-2 , 9.25 inch axle (1), behind the inner axle shaft seal or the inner axle shaft bearing as necessary. 5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 . 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01 . Installation Procedure 1. Install the right side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). 2. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 3. Install the inner axle shaft into the inner axle shaft housing. Carefully tap the inner axle shaft into place with a soft-faced mallet. 4. Install the inner axle shaft and clutch fork assembly components into the inner shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). 5. Install the inner axle shaft and housing assembly to the differential carrier case assembly. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7764 6. If both the left side bearing and seal was removed, perform the following step. Install the left side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). 7. If both the left side bearing and seal was removed, perform the following step. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 8. If both the left side bearing and seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 9. If both the left side bearing and seal was removed, perform the following step. Install the front differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Service and Repair)Differential Carrier Assembly Replacement (2500 4WD) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7765 10. If only the left side seal was removed, perform the following step. Install the seal using the J 45225 and a soft-faced mallet. Tap only on the center portion of the J 45225 in order to drive the seal in evenly. 11. If only the left side seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 12. If servicing the 8.25 inch axle, install the shock module. Refer to Shock Absorber and Spring Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Shock Absorber/Shock Absorber and Spring Assembly Replacement). 13. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 14. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft bolts and tighten to 79 Nm (58 lb ft). 15. Fill the differential carrier assembly. Use the correct fluid. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7766 16. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7767 Seals and Gaskets: Service and Repair Rear Drive Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement Drive Pinion Flange/Yoke and/or Oil Seal Replacement Special Tools * J 8614-01 - Flange Holder and Remover * J 22388 - Pinion Oil Seal Installer * J 44414 - Pinion Oil Seal Installer Removal Procedure Note: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Remove the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 4. Remove the rear disc brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). Note: The following procedure is for the 10.5 or 11.5 inch axles. 5. Remove the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). Note: Reference mark the rear propeller shaft to the rear axle pinion yoke. 6. Remove the propeller shaft. * For vehicles equipped the a one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with a two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). Note: Record this measurement for reassembly. 7. Using an inch-pound torque wrench, measure the rotational torque of the differential ring and pinion gear and related components. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7768 8. Place an alignment mark between the pinion and the pinion yoke. Note: * DO NOT reuse the pinion nut, replace with NEW. * For the 11.5 inch axle, use J-34826 socket. 9. Using the J 8614-01 - holder and remover or the J-34826 socket, remove and discard the pinion the pinion nut. Note: Remove the pinion yoke by turning the J 8614-3 (3) clockwise. 10. Using the J 8614-2 (2), J 8614-3 (3) and the J 8614-01 - remover (1), remove the pinion yoke. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7769 Note: DO NOT damage the axle housing. 11. Using a suitable tool, remove the pinion oil seal. Installation Procedure 1. Using the J 22388 - installer , install the new pinion oil seal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7770 2. Apply the proper sealant to the splines of the pinion yoke. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid Differential/Specifications/Fluid Type Specifications). 3. Align the reference marks and install the pinion yoke. Caution: Refer to Pinion Flange/Yoke Installation Caution (See: Service Precautions/Vehicle Damage Warnings/Pinion Flange/Yoke Installation Caution). Note: Tap the pinion yoke until a few threads show through the pinion yoke. 4. Using a soft faced hammer, seat the pinion yoke onto the pinion shaft. 5. Install the washer and a NEW pinion nut. Note: * If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. * For the 11.5 inch axle, use J-34826 socket. 6. Holding the J 8614-01 - holder or the J-34826 socket, tighten the pinion nut until the pinion end play is just taken up. 7. Rotate the pinion while tightening the nut to seat the bearings. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7771 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Compare this measurement with the rotating torque recorded during removal. 8. Using an inch pound torque wrench and tightening in small increments, measure the rotating torque of the pinion until the reading is greater than 0.40-0.57 Nm (3-5 lb in) , the rotational torque noted at removal. Note: Recheck the rotating torque and adjust if necessary. 9. Once the specified torque is obtained, rotate the pinion several times to seat the bearings. Note: Reference mark the rear propeller shaft to the rear axle pinion yoke. 10. Install the propeller shaft. * For vehicles equipped the a one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with a two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). Note: The following procedure is for the 10.5 or 11.5 inch axles. 11. Install the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). 12. Install the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 13. Install the rear disc brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 14. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 15. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)). 16. Remove the support and lower the vehicle. Rear Axle Shaft and/or Gasket Replacement Rear Axle Shaft and/or Gasket Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7772 Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Special Tools * J 2222-C - Wheel Bearing Nut Wrench * J 8092 - Universal Driver Handle - 3/4 x 10 inch * J 24426 - Outer Wheel Bearing Race Installer * J 24427 - Inner Wheel Bearing Race Installer * J 44419 - Hub Bearing Installer * J 44420 - Differential Bearing Installer For equivalent regional tools, refer to Special Tools (See: Steering and Suspension/Suspension/Tools and Equipment/Rear Suspension). Removal Procedure Note: * The wheel speed sensor ring is NOT serviced separately. The hub and wheel speed senor ring are serviced as an assembly. * The rear axle hub seal must be replaced anytime the rear axle hub assembly is removed from the axle housing. * The wheel studs are serviced separately from the rear axle hub. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) Lifting and Jacking the Vehicle. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ) Tire and Wheel Removal and Installation. Note: In the following service procedure, it is not necessary to remove the brake caliper from the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7773 3. Remove the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) Rear Brake Caliper Bracket Replacement. 4. Remove the rear axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) Rear Axle Shaft and/or Gasket Replacement. 5. Remove the rear axle nut retaining ring. 6. Remove the rear wheel bearing adjuster key. 7. Using the J 2222-C - wrench , remove the rear wheel bearing adjuster nut. Note: If the oil seal remains on the axle hub, remove the seal using a suitable seal removal tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7774 8. Remove the rear axle hub from the axle housing. 9. Remove the rear brake rotor, if necessary. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) Rear Brake Rotor Replacement. 10. Using a suitable seal removal tool, remove the oil seal from the wheel hub. 11. Remove the inner hub bearing. 12. Using a brass drift and a hammer, remove the inner hub bearing cup. 13. Remove the retaining ring from the wheel hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7775 14. Using the J 24426 - installer (2) and the J 8092 - handle (1), remove the outer hub bearing and bearing cup. 15. For those vehicles equipped with RPO code JH6, use the J 45270 (1) to remove the wheel studs (2). 16. For those vehicles equipped with RPO code JH7, use a hydraulic press to remove the wheel studs. 17. Remove the rear brake disc from the rear axle hub. Installation Procedure 1. For vehicles equipped RPO code JH7, position the brake rotor on the rear axle hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7776 2. Position the wheel stud in the rear axle hub. 3. Using washers and a wheel nut, tighten the wheel nut until the wheel stud is fully seated in the rear axle hub. 4. Remove the lug nut and the washers. 5. Lubricate the following with a light coat of high melting point EP bearing lubricant: * The outer wheel bearing * The inner wheel bearing * The outer wheel bearing cup * The inner wheel bearing cup * The axle hub spindle 6. Install the outer bearing into the rear axle hub. Note: Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 7. Using the J 44419 - installer (2) and the J 8092 - handle (1), install the outer bearing cup into the rear axle hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7777 Note: Ensure that the retaining ring is fully and evenly seated in the groove. 8. Install the retaining ring into the groove. Note: Ensure that the outer bearing assembly rotates freely in the hub 9. Using the J 24426 - installer (2) and the J 8092 - handle (1), turn the rear axle hub over and seat the outer bearing assembly against the retaining ring. 10. Turn the rear axle hub over and install the inner bearing cup. 11. Using the J 24427 - installer (2) and the J 8092 - handle (1), install the inner bearing cup into the wheel hub. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7778 12. Install the inner bearing. Note: Ensure the seal is fully seated in the hub bore. 13. Using the J 44420 - installer (2) and the J 8092 - handle (1), install the new oil seal. 14. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Note: If the rear axle hub assembly does not fully seat itself onto the axle shaft spindle and is removed, the rear axle hub seal must be replaced. 15. Install the rear axle hub. Note: Install the rear wheel bearing adjuster nut by hand. 16. Using the J 2222-C - wrench , adjust the rear wheel bearings. Refer to Wheel Bearing Adjustment (See: Service and Repair/Procedures/Rear Drive Axle/Wheel Bearing Adjustment) Wheel Bearing Adjustment Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7779 17. Install the rear axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) Rear Axle Shaft and/or Gasket Replacement. 18. Install the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) Rear Brake Caliper Bracket Replacement. 19. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) Tire and Wheel Removal and Installation. 20. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)) Rear Axle Lubricant Level Inspection. 21. Remove the supports and lower the vehicle. Drive Pinion Housing and/or Seal Replacement Drive Pinion Housing and/or Seal Replacement Special Tools * J 8092 - Universal Driver Handle 3/4 x 10 inch * J 8608 - Pinion bearing Cup Installer * J 24433 - Pinion Bearing Installer * J 37624 - Pinion Bearing Installer * J 44414 - Pinion Oil Seal Installer Removal Procedure Note: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Drain the axle lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 3. Remove the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). 4. Remove the rear propeller shaft. * For vehicles equipped with the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with the two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 5. Remove the drive pinion flange/yoke and/or oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). 6. Using a hydraulic press and an appropriate tool, remove the pinion. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7780 7. Remove the collapsible spacer. Note: When performing the following service procedure, move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 8. Using a hammer and a brass drift in the slots provided, remove the outer pinion bearing cup. Note: When performing the following service procedure, move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 9. Using a hammer and a brass drift in the slots provided, remove the inner pinion bearing cup. Installation Procedure 1. Using the J 37624 (2) and the J 8092 (1), Install the inner pinion bearing cup into the pinion gear bearing retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7781 2. Using the J 8608 (2) and the J 8092 (1), install the outer pinion bearing cup into the pinion gear bearing retainer. 3. Apply sealant to surface of the selective shim. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid - Differential/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the pinion gear bearing retainer and bolts tighten to 88 Nm (65 lb ft). 5. Install the drive pinion flange/yoke and/or oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). 6. Install the propeller shaft. * For vehicles equipped with the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with the two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 7. Install the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). 8. Fill the axle with axle lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement )Differential Oil Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 9. Remove the support and lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement Axle Bearing: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement Rear Axle Shaft Seal and/or Bearing Replacement Special Tools * J 2619-01 - Slide Hammer W 1/2 x 13 Adapter * J 8092 - Universal Driver Handle 3/4 x 10 inch * J 21128 - Axle Pinion Oil Seal Installer * J 23690 - Axle Bearing Installer * J 44685 - Rear Axle Seal and Bearing Remover * J 45857 - VSES Wheel Bearing Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 4. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Axle Shaft Assembly/Axle Shaft/Service and Repair). Note: If the vehicle is equipped with VSES, proceed to step 5. 5. Using the J 44685 - remover (1) and the J 2619-01 - hammer (2), remove the rear axle shaft seal. 6. Using the J 45857 - remover (1) and the J 2619-01 - hammer (2), remove the rear axle shaft seal, bearing and the wheel speed sensor reluctor ring, if equipped. Installation Procedure 1. Install the rear wheel speed sensor reluctor ring, if equipped. * For vehicles with the HP2 (Hybrid) option, refer to Rear Wheel Speed Sensor Ring Replacement (). * For vehicles that are NON-Hybrid less than 3900 kg (8600 lbs) GVW, refer to Rear Wheel Speed Sensor Ring Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Ring Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). * For vehicles that are NON-Hybrid greater than/equal to 3900 kg (8600 lbs) GVW, refer to Rear Wheel Speed Sensor Ring Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Ring Replacement/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 7787 Note: Ensure that the axle shaft bearing is fully seated in the rear axle shaft housing. 2. Using the J 23690 - installer (1) and the J 8092 - driver (2), install the axle shaft bearing. 3. Using the J 21128 - installer , install the axle shaft seal. 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the rear axle shaft. Refer to Rear Axle Shaft Replacement (See: Axle Shaft Assembly/Axle Shaft/Service and Repair). 6. Install the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. Fill the rear axle. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Removal and Replacement). 9. Remove the support and lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 7788 Axle Bearing: Service and Repair Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Special Tools * J 2222-C - Wheel Bearing Nut Wrench * J 8092 - Universal Driver Handle - 3/4 x 10 inch * J 24426 - Outer Wheel Bearing Race Installer * J 24427 - Inner Wheel Bearing Race Installer * J 44419 - Hub Bearing Installer * J 44420 - Differential Bearing Installer For equivalent regional tools, refer to Special Tools (See: Steering and Suspension/Suspension/Tools and Equipment/Rear Suspension). Removal Procedure Note: * The wheel speed sensor ring is NOT serviced separately. The hub and wheel speed senor ring are serviced as an assembly. * The rear axle hub seal must be replaced anytime the rear axle hub assembly is removed from the axle housing. * The wheel studs are serviced separately from the rear axle hub. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) Lifting and Jacking the Vehicle. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ) Tire and Wheel Removal and Installation. Note: In the following service procedure, it is not necessary to remove the brake caliper from the bracket. 3. Remove the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) Rear Brake Caliper Bracket Replacement. 4. Remove the rear axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) Rear Axle Shaft and/or Gasket Replacement. 5. Remove the rear axle nut retaining ring. 6. Remove the rear wheel bearing adjuster key. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 7789 7. Using the J 2222-C - wrench , remove the rear wheel bearing adjuster nut. Note: If the oil seal remains on the axle hub, remove the seal using a suitable seal removal tool. 8. Remove the rear axle hub from the axle housing. 9. Remove the rear brake rotor, if necessary. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) Rear Brake Rotor Replacement. 10. Using a suitable seal removal tool, remove the oil seal from the wheel hub. 11. Remove the inner hub bearing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 7790 12. Using a brass drift and a hammer, remove the inner hub bearing cup. 13. Remove the retaining ring from the wheel hub. 14. Using the J 24426 - installer (2) and the J 8092 - handle (1), remove the outer hub bearing and bearing cup. 15. For those vehicles equipped with RPO code JH6, use the J 45270 (1) to remove the wheel studs (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 7791 16. For those vehicles equipped with RPO code JH7, use a hydraulic press to remove the wheel studs. 17. Remove the rear brake disc from the rear axle hub. Installation Procedure 1. For vehicles equipped RPO code JH7, position the brake rotor on the rear axle hub. 2. Position the wheel stud in the rear axle hub. 3. Using washers and a wheel nut, tighten the wheel nut until the wheel stud is fully seated in the rear axle hub. 4. Remove the lug nut and the washers. 5. Lubricate the following with a light coat of high melting point EP bearing lubricant: * The outer wheel bearing * The inner wheel bearing * The outer wheel bearing cup * The inner wheel bearing cup * The axle hub spindle Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 7792 6. Install the outer bearing into the rear axle hub. Note: Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 7. Using the J 44419 - installer (2) and the J 8092 - handle (1), install the outer bearing cup into the rear axle hub. Note: Ensure that the retaining ring is fully and evenly seated in the groove. 8. Install the retaining ring into the groove. Note: Ensure that the outer bearing assembly rotates freely in the hub 9. Using the J 24426 - installer (2) and the J 8092 - handle (1), turn the rear axle hub over and seat the outer bearing assembly against the retaining ring. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 7793 10. Turn the rear axle hub over and install the inner bearing cup. 11. Using the J 24427 - installer (2) and the J 8092 - handle (1), install the inner bearing cup into the wheel hub. 12. Install the inner bearing. Note: Ensure the seal is fully seated in the hub bore. 13. Using the J 44420 - installer (2) and the J 8092 - handle (1), install the new oil seal. 14. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 7794 Note: If the rear axle hub assembly does not fully seat itself onto the axle shaft spindle and is removed, the rear axle hub seal must be replaced. 15. Install the rear axle hub. Note: Install the rear wheel bearing adjuster nut by hand. 16. Using the J 2222-C - wrench , adjust the rear wheel bearings. Refer to Wheel Bearing Adjustment (See: Differential Assembly/Service and Repair/Procedures/Rear Drive Axle/Wheel Bearing Adjustment) Wheel Bearing Adjustment 17. Install the rear axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) Rear Axle Shaft and/or Gasket Replacement. 18. Install the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) Rear Brake Caliper Bracket Replacement. 19. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) Tire and Wheel Removal and Installation. 20. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)) Rear Axle Lubricant Level Inspection. 21. Remove the supports and lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair Axle Shaft: Service and Repair Rear Axle Shaft Replacement Special Tools * J 2619-01 - Slide Hammer W/1/2 x 13 Adapter * J 45859 - Axle Shaft Remover/Installer For equivalent regional tools, refer to Special Tools (See: Differential Assembly/Tools and Equipment/Rear Drive Axle). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the wheel speed sensor. * For Hybrid vehicles, refer to Rear Wheel Speed Sensor Replacement (). * For non Hybrid vehicles (1500 series), refer to Rear Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). * For non Hybrid vehicles (2500 series), refer to Rear Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW). 4. Remove the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 5. Remove the brake caliper mounting bracket, if equipped. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)). 6. Remove the rear axle housing cover and gasket. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 7. Remove the and discard differential pinion gear shaft bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 7799 Note: For those vehicles NOT equipped with the locking differential proceed to step 8. If the vehicle is equipped WITH the locking differential, proceed to step 9 and 10. 8. Remove the differential pinion gear shaft. Note: Rotate the differential case until the differential pinion shaft just touches the rear axle housing. 9. Remove the differential pinion gear shaft part way from the differential case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 7800 10. Use a screw driver, or similar tool to rotate the lock (1) until the lock (1) aligns with the thrust block. 11. Push in on the rear axle shaft (2) and remove the lock (1). Note: If the rear axle shaft is difficult to remove, proceed to step 14. 12. Remove the rear drum brake axle shaft (2) from the rear axle assembly (1), if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 7801 Note: If the rear axle shaft is difficult to remove, proceed to step 14. 13. Remove the rear disc brake axle shaft (1) from the rear axle assembly (2), if equipped 14. Using the J 2619-01 - hammer (2) and the J 45859 - remover/installer (1), remove the rear axle shaft from the rear axle assembly. 15. Replace the rear axle shaft seal and or bearing, if needed. Refer to Rear Axle Shaft Seal and/or Bearing Replacement (See: Axle Bearing/Service and Repair/Rear Axle Shaft Seal and/or Bearing Replacement). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 7802 Note: When installing the rear axle shaft, ensure that the seal is not damaged. 1. Install the disc brake axle shaft (1) in the rear axle assembly (2), if equipped. 2. Install the drum brake axle shaft (2) in the rear axle assembly (1), if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 7803 Note: In steps 3 and 4, pull out on the axle shaft after the lock has been installed to ensure that the lock is seated properly. 3. Install the lock (1) in the rear axle (2), without a locking differential. 4. Install the lock (1) on the rear axle shaft (3), with a locking differential. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 7804 Note: On axles with a locking differential, keep the differential pinion shaft slightly withdrawn. 5. Install the differential pinion gear shaft. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the NEW differential pinion gear shaft bolt and tighten to 34 Nm (25 lb ft) for the 8.6 inch axle and 50 Nm (37 lb ft) for the 9.5 inch axle. Note: End play is the in and out movement of the rear axle shaft. Radial play is the up and own movement in the rear axle shaft. 7. Check the rear axle shaft end play and the radial play. The rear axle shaft end play should be 0.012 inch per side and the radial play should be 0.002-0.003 inch. If the rear axle shaft is NOT within the specifications, replace any excessively worn parts. 8. Install the rear axle housing cover and gasket. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 9. Install the wheel speed sensor. * For Hybrid vehicles, refer to Rear Wheel Speed Sensor Replacement (). * For non Hybrid vehicles (1500 series), refer to Rear Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). * For non Hybrid vehicles (2500 series), refer to Rear Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW). 10. Install the brake caliper mounting bracket, if equipped. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 7805 Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)). 11. Install the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 13. Remove the support and lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement Wheel Drive Shaft Inner Joint and Boot Replacement Special Tools * J-35910 - Drive Axle Seal Clamp Pliers * J-36652-1 - Drive Axle Clamp Swage Tool * J-36652-98 - Axle Swage Tool Disassemble Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). Note: Use caution when removing the tripot housing (1). 2. Using the appropriate tool, remove the boot clamp (2). 3. Remove the tripot housing (1). Note: If using denatured alcohol or any other recommend cleaning solvent, allow the tripot housing to air dry. 4. Remove any grease from of the housing (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7810 5. Using side cutters, remove the small boot retaining clamp (4). 6. Using the appropriate tool, remove the retaining ring (1), then the spider assembly (2), and the boot (3). 7. Using the appropriate tool, remove the any rust in the seal mounting area (grooves) (1). 8. If any of the internal components of the tripot assembly are found to be damaged or have excessive wear, replace the tripot as an assembly. Assemble Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7811 1. Position the boot (1) so that it is seated properly in the groove (2) in the wheel drive shaft (3). 2. Install the small boot clamp (2) on the boot (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7812 3. Using the J-35910 - pliers , a breaker bar, and a torque wrench (1), close the boot clamp (2) until the gap (3) measures 2.15 mm (0.085 inch). 4. Install the spider assembly (2). 5. Using the appropriate tool, install the retaining ring (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7813 Note: Position the boot clamp so that it is at the small end of the boot. 6. Install the tripot assembly (1) and the boot clamp (2) 7. Place approximately half of the lubricant (2) in the boot (1) and the remaining half in the tripot housing (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7814 Note: Pinch the slightly by hand in order to distort it into an oval shape. 8. Install the boot (1) and the boot clamp (2) on the tripot housing (3). 9. For the 1500 models, assemble the bolts and the support plate to the base of the J-36652-98 tool and secure the base in a vise. 10. For the 2500, 3500 models, assemble the bolts and the support plate to the base of the J-36652-1 - tool and secure the base in a vise. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7815 11. Position the tripot end of the wheel drive shaft assembly into the base of the J-36652-98 - tool for the 1500 models or J-36652-1 - tool for the 2500, 3500 models. 12. Install the top half of the J-36652-98 - Tool for the 1500 models or J-36652-1 - tool for the 2500, 3500 models. 13. Align the boot clamp (2) and the clamp. Note: Hand tighten the bolts until the bolts are snug. 14. Insert the bolts. 15. Align the tripot boot, tripot housing, and the boot clamp. Note: Alternate between the bolts until both sides of the top half of the tool touch the bottom half. 16. Tighten each bolt 180 degrees at a time. 17. Loosen the bolts and remove the halfshaft assembly from the tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7816 18. Inspect the inboard stroke position. * Measurement A for the 1500 models should be 170 mm (6 11/16 inch). * Measurement A for the 2500, 3500, should be 178 mm (7 inch). 19. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7817 Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement Wheel Drive Shaft Outer Joint and Boot Replacement Special Tools * J 8059 Snap Ring Pliers * J 35910 Drive Axle Seal Clamp Pliers * J 36652-1 Drive Axle Clamp Swage Tool * J 36652-2 Axle Swage Tool Removal Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). 2. Remove the wheel drive shaft seal cover, if applicable. Refer to Front Wheel Drive Shaft Seal Protector Replacement (See: Service and Repair). Note: Use caution when using the hand grinder by the CV joint outer race (1). 3. Use a hand grinder to cut through the swage ring (2). 4. Use side cutters to cut off the small boot clamp (4). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7818 5. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 6. Wipe all grease away from the face of the CV joint. 7. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2). 8. Spread the snap ring ears apart using J 8059 (or equivalent). 9. Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 10. Discard the old CV joint boot (5). 11. Place a brass drift against the CV joint cage (1). 12. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 13. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 14. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7819 15. Repeat this process to remove all six of the balls. 16. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 17. Lift out the cage (4) and the inner race. 18. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 19. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 1. The inner and outer race assemblies 2. The CV joint cage 3. The chrome alloy balls 20. Dry all the parts. 21. Check the CV joint assembly for unusual wear, cracks, or other damage. 22. Replace any damaged parts. 23. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7820 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. 3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7821 6. Insert the cage (4) and inner race into the outer race (1). 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7822 12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1) onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove (3) on the halfshaft bar. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7823 16. Secure the small boot clamp (1) using J 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the small clamp (1) to 136 Nm (100 lb ft). 17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. 18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the distorted swage ring (2) over the large diameter of the boot (1). Note: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation. 20. Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint (4) is in the proper position. 21. Pull on the CV joint (4) to verify engagement. 22. Slide the large diameter of the CV joint boot (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4). 23. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4), using the following procedure: 24. For the 1500 models, assemble the bolts and the support plate to the base of the J 36652-1 and secure the base in a vise. For the 2500 and 3500 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7824 models, use the J 36652-2 . 25. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of J 36652-1 or J 36652-2 . 26. Align the following during this procedure: * The CV joint boot (3) * The CV joint assembly (1) * The swage ring (2) 27. Install the top half of J 36652-1 or J 36652-2 onto the lower half of the tool, over the CV joint boot (3) and the CV joint assembly (1). 28. Align the swage ring (2) and the swage ring clamp. 29. Insert the bolts into J 36652-1 or J 36652-2 . Hand tighten the bolts until the bolts are snug. Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half of the tool. 30. Loosen the bolts and remove the halfshaft assembly from the tool. 31. Install the wheel drive shaft seal cover, if applicable. Refer to Front Wheel Drive Shaft Seal Protector Replacement (See: Service and Repair). 32. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement Wheel Drive Shaft Inner Joint and Boot Replacement Special Tools * J-35910 - Drive Axle Seal Clamp Pliers * J-36652-1 - Drive Axle Clamp Swage Tool * J-36652-98 - Axle Swage Tool Disassemble Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). Note: Use caution when removing the tripot housing (1). 2. Using the appropriate tool, remove the boot clamp (2). 3. Remove the tripot housing (1). Note: If using denatured alcohol or any other recommend cleaning solvent, allow the tripot housing to air dry. 4. Remove any grease from of the housing (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7829 5. Using side cutters, remove the small boot retaining clamp (4). 6. Using the appropriate tool, remove the retaining ring (1), then the spider assembly (2), and the boot (3). 7. Using the appropriate tool, remove the any rust in the seal mounting area (grooves) (1). 8. If any of the internal components of the tripot assembly are found to be damaged or have excessive wear, replace the tripot as an assembly. Assemble Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7830 1. Position the boot (1) so that it is seated properly in the groove (2) in the wheel drive shaft (3). 2. Install the small boot clamp (2) on the boot (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7831 3. Using the J-35910 - pliers , a breaker bar, and a torque wrench (1), close the boot clamp (2) until the gap (3) measures 2.15 mm (0.085 inch). 4. Install the spider assembly (2). 5. Using the appropriate tool, install the retaining ring (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7832 Note: Position the boot clamp so that it is at the small end of the boot. 6. Install the tripot assembly (1) and the boot clamp (2) 7. Place approximately half of the lubricant (2) in the boot (1) and the remaining half in the tripot housing (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7833 Note: Pinch the slightly by hand in order to distort it into an oval shape. 8. Install the boot (1) and the boot clamp (2) on the tripot housing (3). 9. For the 1500 models, assemble the bolts and the support plate to the base of the J-36652-98 tool and secure the base in a vise. 10. For the 2500, 3500 models, assemble the bolts and the support plate to the base of the J-36652-1 - tool and secure the base in a vise. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7834 11. Position the tripot end of the wheel drive shaft assembly into the base of the J-36652-98 - tool for the 1500 models or J-36652-1 - tool for the 2500, 3500 models. 12. Install the top half of the J-36652-98 - Tool for the 1500 models or J-36652-1 - tool for the 2500, 3500 models. 13. Align the boot clamp (2) and the clamp. Note: Hand tighten the bolts until the bolts are snug. 14. Insert the bolts. 15. Align the tripot boot, tripot housing, and the boot clamp. Note: Alternate between the bolts until both sides of the top half of the tool touch the bottom half. 16. Tighten each bolt 180 degrees at a time. 17. Loosen the bolts and remove the halfshaft assembly from the tool. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7835 18. Inspect the inboard stroke position. * Measurement A for the 1500 models should be 170 mm (6 11/16 inch). * Measurement A for the 2500, 3500, should be 178 mm (7 inch). 19. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7836 Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement Wheel Drive Shaft Outer Joint and Boot Replacement Special Tools * J 8059 Snap Ring Pliers * J 35910 Drive Axle Seal Clamp Pliers * J 36652-1 Drive Axle Clamp Swage Tool * J 36652-2 Axle Swage Tool Removal Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). 2. Remove the wheel drive shaft seal cover, if applicable. Refer to Front Wheel Drive Shaft Seal Protector Replacement (See: Service and Repair). Note: Use caution when using the hand grinder by the CV joint outer race (1). 3. Use a hand grinder to cut through the swage ring (2). 4. Use side cutters to cut off the small boot clamp (4). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7837 5. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 6. Wipe all grease away from the face of the CV joint. 7. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2). 8. Spread the snap ring ears apart using J 8059 (or equivalent). 9. Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 10. Discard the old CV joint boot (5). 11. Place a brass drift against the CV joint cage (1). 12. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 13. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 14. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7838 15. Repeat this process to remove all six of the balls. 16. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 17. Lift out the cage (4) and the inner race. 18. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 19. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 1. The inner and outer race assemblies 2. The CV joint cage 3. The chrome alloy balls 20. Dry all the parts. 21. Check the CV joint assembly for unusual wear, cracks, or other damage. 22. Replace any damaged parts. 23. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7839 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. 3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7840 6. Insert the cage (4) and inner race into the outer race (1). 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7841 12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1) onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove (3) on the halfshaft bar. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7842 16. Secure the small boot clamp (1) using J 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the small clamp (1) to 136 Nm (100 lb ft). 17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. 18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the distorted swage ring (2) over the large diameter of the boot (1). Note: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation. 20. Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint (4) is in the proper position. 21. Pull on the CV joint (4) to verify engagement. 22. Slide the large diameter of the CV joint boot (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4). 23. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4), using the following procedure: 24. For the 1500 models, assemble the bolts and the support plate to the base of the J 36652-1 and secure the base in a vise. For the 2500 and 3500 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 7843 models, use the J 36652-2 . 25. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of J 36652-1 or J 36652-2 . 26. Align the following during this procedure: * The CV joint boot (3) * The CV joint assembly (1) * The swage ring (2) 27. Install the top half of J 36652-1 or J 36652-2 onto the lower half of the tool, over the CV joint boot (3) and the CV joint assembly (1). 28. Align the swage ring (2) and the swage ring clamp. 29. Insert the bolts into J 36652-1 or J 36652-2 . Hand tighten the bolts until the bolts are snug. Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half of the tool. 30. Loosen the bolts and remove the halfshaft assembly from the tool. 31. Install the wheel drive shaft seal cover, if applicable. Refer to Front Wheel Drive Shaft Seal Protector Replacement (See: Service and Repair). 32. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Seals and Gaskets: Service and Repair Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Special Tools * J 2222-C - Wheel Bearing Nut Wrench * J 8092 - Universal Driver Handle - 3/4 x 10 inch * J 24426 - Outer Wheel Bearing Race Installer * J 24427 - Inner Wheel Bearing Race Installer * J 44419 - Hub Bearing Installer * J 44420 - Differential Bearing Installer For equivalent regional tools, refer to Special Tools (See: Steering and Suspension/Suspension/Tools and Equipment/Rear Suspension). Removal Procedure Note: * The wheel speed sensor ring is NOT serviced separately. The hub and wheel speed senor ring are serviced as an assembly. * The rear axle hub seal must be replaced anytime the rear axle hub assembly is removed from the axle housing. * The wheel studs are serviced separately from the rear axle hub. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) Lifting and Jacking the Vehicle. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ) Tire and Wheel Removal and Installation. Note: In the following service procedure, it is not necessary to remove the brake caliper from the bracket. 3. Remove the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) Rear Brake Caliper Bracket Replacement. 4. Remove the rear axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Rear Axle Shaft and/or Gasket Replacement) Rear Axle Shaft and/or Gasket Replacement. 5. Remove the rear axle nut retaining ring. 6. Remove the rear wheel bearing adjuster key. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement > Page 7848 7. Using the J 2222-C - wrench , remove the rear wheel bearing adjuster nut. Note: If the oil seal remains on the axle hub, remove the seal using a suitable seal removal tool. 8. Remove the rear axle hub from the axle housing. 9. Remove the rear brake rotor, if necessary. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) Rear Brake Rotor Replacement. 10. Using a suitable seal removal tool, remove the oil seal from the wheel hub. 11. Remove the inner hub bearing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement > Page 7849 12. Using a brass drift and a hammer, remove the inner hub bearing cup. 13. Remove the retaining ring from the wheel hub. 14. Using the J 24426 - installer (2) and the J 8092 - handle (1), remove the outer hub bearing and bearing cup. 15. For those vehicles equipped with RPO code JH6, use the J 45270 (1) to remove the wheel studs (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement > Page 7850 16. For those vehicles equipped with RPO code JH7, use a hydraulic press to remove the wheel studs. 17. Remove the rear brake disc from the rear axle hub. Installation Procedure 1. For vehicles equipped RPO code JH7, position the brake rotor on the rear axle hub. 2. Position the wheel stud in the rear axle hub. 3. Using washers and a wheel nut, tighten the wheel nut until the wheel stud is fully seated in the rear axle hub. 4. Remove the lug nut and the washers. 5. Lubricate the following with a light coat of high melting point EP bearing lubricant: * The outer wheel bearing * The inner wheel bearing * The outer wheel bearing cup * The inner wheel bearing cup * The axle hub spindle Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement > Page 7851 6. Install the outer bearing into the rear axle hub. Note: Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 7. Using the J 44419 - installer (2) and the J 8092 - handle (1), install the outer bearing cup into the rear axle hub. Note: Ensure that the retaining ring is fully and evenly seated in the groove. 8. Install the retaining ring into the groove. Note: Ensure that the outer bearing assembly rotates freely in the hub 9. Using the J 24426 - installer (2) and the J 8092 - handle (1), turn the rear axle hub over and seat the outer bearing assembly against the retaining ring. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement > Page 7852 10. Turn the rear axle hub over and install the inner bearing cup. 11. Using the J 24427 - installer (2) and the J 8092 - handle (1), install the inner bearing cup into the wheel hub. 12. Install the inner bearing. Note: Ensure the seal is fully seated in the hub bore. 13. Using the J 44420 - installer (2) and the J 8092 - handle (1), install the new oil seal. 14. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement > Page 7853 Note: If the rear axle hub assembly does not fully seat itself onto the axle shaft spindle and is removed, the rear axle hub seal must be replaced. 15. Install the rear axle hub. Note: Install the rear wheel bearing adjuster nut by hand. 16. Using the J 2222-C - wrench , adjust the rear wheel bearings. Refer to Wheel Bearing Adjustment (See: Differential Assembly/Service and Repair/Procedures/Rear Drive Axle/Wheel Bearing Adjustment) Wheel Bearing Adjustment 17. Install the rear axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Rear Axle Shaft and/or Gasket Replacement) Rear Axle Shaft and/or Gasket Replacement. 18. Install the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) Rear Brake Caliper Bracket Replacement. 19. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) Tire and Wheel Removal and Installation. 20. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)) Rear Axle Lubricant Level Inspection. 21. Remove the supports and lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement > Page 7854 Seals and Gaskets: Service and Repair Rear Axle Shaft and/or Gasket Replacement Rear Axle Shaft and/or Gasket Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 7858 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Drive Shaft Nut ......................................................................................................................... .................................................... 240 Nm (177 lb ft) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair Center Support: Service and Repair Propeller Shaft Center Support Bearing Replacement Special Tools * J 22833 Input/Countershaft Race Installer * J 24433 Pinion Cone & Side Bearing Installer * J 39477 Puller Kit Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the propeller shaft assembly. Refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 3. Install the J 39477 (1) on the center bearing assembly (2). 4. Position the J 39477 (1) in a vise 5. Using the J 39477 (1), remove the center bearing assembly (2) from the propeller shaft. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 7867 1. Place the propeller shaft assembly (3) on a block of wood. 2. Position the center bearing assembly (2) on the propeller shaft (3). 3. Using the J 22833 (1), install the center bearing assembly (2) on the propeller shaft (3). 4. For HD vehicles, use the J 24433 (1) to install the propeller shaft boot retainer (2) on the center bearing assembly (3). 5. Install the propeller shaft assembly. Refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement) 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Mechanical Specifications Drive/Propeller Shaft: Mechanical Specifications Fastener Tightening Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Mechanical Specifications > Page 7872 Drive/Propeller Shaft: Fluid Type Specifications Adhesives, Fluids, Lubricants, and Sealers Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 7873 Drive/Propeller Shaft: Locations Driveline Disassembled Views Front Propeller Shaft 1 - Propeller Shaft Universal Joint 2 - Propeller Shaft Tube 3 - Propeller Shaft Universal Joint 4 Propeller Shaft Slip Yoke 5 - Propeller Shaft Rear Slip Yoke Boot Clamp - Front 6 - Propeller Shaft Rear Slip Yoke Boot One-Piece Propeller Shaft Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 7874 1 - Propeller Shaft Slip Yoke 2 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 3 Propeller Shaft Universal Joint 4 - Propeller Shaft Tube 5 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 6 - Propeller Shaft Universal Joint 7 - Propeller Shaft Bearing Retainer 8 Propeller Shaft Bearing Retainer Bolt Two-Piece Propeller Shaft 1 - Propeller Shaft Slip Yoke 2 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 3 Propeller Shaft Universal Joint 4 - Propeller Shaft Tube 5 - Propeller Shaft Bearing Shield 6 Propeller Shaft Bearing Insulator 7 - Propeller Shaft Bearing Support Bolt 8 - Propeller Shaft Bearing Support 9 - Propeller Shaft Retainer 10 - Propeller Shaft Center Support Bearing 11 Propeller Shaft Retainer 12 - Propeller Shaft Bearing Slinger 13 - Propeller Shaft Universal Joint 14 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 15 - Propeller Shaft Tube 16 Propeller Shaft Universal Joint 17 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 18 - Propeller Shaft Slip Yoke 19 - Propeller Shaft Slip Yoke Boot Clamp 20 - Propeller Shaft Slip Yoke Boot 21 - Propeller Shaft Slip Yoke Boot Clamp Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 7875 Drive/Propeller Shaft: Description and Operation Propeller Shaft Description and Operation The propeller shaft is a tube with universal joints at both ends which do not require periodic maintenance, that transmit power from the transfer case or transmission output shaft to the differential. Front Propeller Shaft Description The front propeller shaft transmits rotating force from the transfer case to the front differential when the transfer case is engaged. The front propeller shaft connects to the transfer case using a splined slip joint. One Piece Propeller Shaft Description A 1 piece propeller shaft uses a splined slip joint to connect the driveline to the transmission or transfer case. Two Piece Propeller Shaft Description There are 3 universal joints used on the two piece propeller shaft, A center bearing assembly is used to support the propeller shaft connection point, and help isolate the vehicle from vibration. Propeller Shaft Phasing Description The propeller shaft is designed and built with the yoke lugs (ears) in line with each other. This produces the smoothest running shaft possible. A propeller shaft designed with built in yoke lugs in line is known as in - phase. An out of phase propeller shaft often causes vibration. The propeller shaft generates vibration from speeding up and slowing down each time the universal joint goes around. The vibration is the same as a person snapping a rope and watching the wave reaction flow to the end. An in phase propeller shaft is similar to 2 persons snapping a rope at the same time and watching the waves meet and cancel each other out. A total cancellation of vibration produces a smooth flow of power in the drive line. All splined shaft slip yokes are keyed in order to ensure proper phasing. Universal Joint Description The universal joint is connected to the propeller shaft. The universal consist of 4 caps with needle bearings and grease seals mounted on the trunnions of a cross or spider. These bearings and caps are greased at the factory and no periodic maintenance is required. There are 2 universal joints used in a one piece propeller shaft and 3 used in two piece propeller shaft. The bearings and caps are pressed into the yokes and held in place with snap rings, except for 2 bearings on some models witch are strapped onto the pinion flange of the differential. Universal joints are designed to handle the effects of various loads and rear axle windup conditions during acceleration and braking. The universal joint operates efficiently and safely within the designed angle variations. when the design angles are exceeded, the operational life of the joint decreases. Center Bearing Description Center bearings support the driveline when using 2 or more propeller shafts. The center bearing is a ball bearing mounted in a rubber cushion that attaches to a frame crossmember. The manufacturer prelubricates and seals the bearing. The cushion allows vertical motion at the driveline and helps isolate the vehicle from vibration. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptoms - Propeller Shaft Drive/Propeller Shaft: Testing and Inspection Symptoms - Propeller Shaft Symptoms - Propeller Shaft Before beginning diagnosis, review the system description and operation in order to familiarize yourself with the system function. Refer to Propeller Shaft Description and Operation (See: Description and Operation). Classifying the Symptom Propeller Shaft symptoms can usually be classified into the following categories: * Leaks * Noises * Vibrations Leak and noise related symptoms are diagnosed within the Propeller Shaft section. For vibration related symptoms, refer to Vibration Diagnosis, Starting Point, and Correction (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Vibration Diagnosis and Correction/Diagnostic Information and Procedures/Vibration Diagnosis, Starting Point, and Correction). Visual/Physical Inspection * Inspect the system for aftermarket devices which could affect the operation of the Propeller Shaft. * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Leak at Front Slip Yoke (See: Leak at Front Slip Yoke) * Universal Joint Noise (See: Universal Joint Noise) * Ping, Snap, or Click Noise (See: Ping, Snap, or Click Noise) * Knock or Clunk Noise (See: Knock or Clunk Noise) * Scraping Noise (See: Scraping Noise) * Squeak Noise (See: Squeak Noise) * Shudder on Acceleration at Low Speed (See: Shudder on Acceleration at Low Speed) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptoms - Propeller Shaft > Page 7878 Drive/Propeller Shaft: Testing and Inspection Knock or Clunk Noise Knock or Clunk Noise Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptoms - Propeller Shaft > Page 7879 Drive/Propeller Shaft: Testing and Inspection Leak at Front Slip Yoke Leak at Front Slip Yoke Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptoms - Propeller Shaft > Page 7880 Drive/Propeller Shaft: Testing and Inspection Ping, Snap, or Click Noise Ping, Snap, or Click Noise Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptoms - Propeller Shaft > Page 7881 Drive/Propeller Shaft: Testing and Inspection Symptoms - Propeller Shaft Symptoms - Propeller Shaft Before beginning diagnosis, review the system description and operation in order to familiarize yourself with the system function. Refer to Propeller Shaft Description and Operation (See: Description and Operation). Classifying the Symptom Propeller Shaft symptoms can usually be classified into the following categories: * Leaks * Noises * Vibrations Leak and noise related symptoms are diagnosed within the Propeller Shaft section. For vibration related symptoms, refer to Vibration Diagnosis, Starting Point, and Correction (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Vibration Diagnosis and Correction/Diagnostic Information and Procedures/Vibration Diagnosis, Starting Point, and Correction). Visual/Physical Inspection * Inspect the system for aftermarket devices which could affect the operation of the Propeller Shaft. * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Leak at Front Slip Yoke (See: Leak at Front Slip Yoke) * Universal Joint Noise (See: Universal Joint Noise) * Ping, Snap, or Click Noise (See: Ping, Snap, or Click Noise) * Knock or Clunk Noise (See: Knock or Clunk Noise) * Scraping Noise (See: Scraping Noise) * Squeak Noise (See: Squeak Noise) * Shudder on Acceleration at Low Speed (See: Shudder on Acceleration at Low Speed) Knock or Clunk Noise Knock or Clunk Noise Leak at Front Slip Yoke Leak at Front Slip Yoke Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptoms - Propeller Shaft > Page 7882 Ping, Snap, or Click Noise Ping, Snap, or Click Noise Scraping Noise Scraping Noise Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptoms - Propeller Shaft > Page 7883 Shudder on Acceleration at Low Speed Shudder on Acceleration at Low Speed Squeak Noise Squeak Noise Universal Joint Noise Universal Joint Noise Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement Drive/Propeller Shaft: Service and Repair Front Propeller Shaft Replacement Front Propeller Shaft Replacement Special Tools J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Note: Before disassembly, observe and accurately reference mark all driveline components relative to the propeller shaft and axles. These items include the following components: * The propeller shafts * The wheel drive shafts * The pinion flanges * The output shafts Assemble all components in the exact relationship to each other as they were prior to removal. Observe all published specifications and torque values, and any measurements obtained prior to disassembly. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the clamp (4) at the transfer case by prying up the exposed end of the clamp with a flat-bladed tool. 3. Reference mark the relationship of the propeller shaft to the front axle pinon yoke. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7886 Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 4. Remove the bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). Note: Do not drop the bearing cap assemblies of the yoke end. 5. Disconnect the propeller shaft (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. 6. Use tape to secure the bearing caps. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7887 7. Remove the boot from the groove on the transfer case output shaft. 8. Remove the propeller shaft from the transfer case output shaft by sliding the propeller shaft forward. 9. Remove the clamp (1) from the propeller shaft boot (2), if needed. 10. Remove the propeller shaft boot (2) from the propeller shaft, if needed. Installation Procedure 1. Inspect the splines of the transfer case output shaft for a sufficient coating of lubricant. If the output shaft does not have a sufficient coating of lubricant, lubricate the shaft with grease, GM P/N 12345879 (Canadian P/N 10953511), or equivalent lubricant meeting GM Specification 9985830. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7888 2. Install the propeller shaft boot (2). 3. Install the propeller shaft boot clamp (1). 4. Install the propeller shaft splines into the transfer case output shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7889 5. Install the propeller shaft (5) to the front axle pinion yoke (1). Align the reference marks made during removal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the yoke retainers (7) and the bolts (6). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 7. Install the boot onto the transfer case output shaft until the boot snaps into the groove on the output shaft. 8. Using the J 43218 to crimp both clamps. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7890 Drive/Propeller Shaft: Service and Repair Rear Propeller Shaft Replacement Rear Propeller Shaft Replacement Removal Procedure Note: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reference mark the propeller shaft to the rear axle pinion yoke. 3. Reference mark the propeller shaft to the transmission or transfer case. 4. Remove the bolts (1) and the yoke retainers (2) from the rear axle pinion yoke (3). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 5. Slide the propeller shaft forward in order to disconnect the propeller shaft from the rear axle pinion yoke. 6. Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transmission or transfer case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7891 7. Remove the propeller shaft from the vehicle. Installation Procedure 1. Inspect the splines of the slip yoke for a sufficient coating of lubricant. If the splines of the slip yoke do not have a sufficient coating of lubricant, lubricate the shaft with lubricant GM P/N 12345879 (Canadian P/N 10953511) or with an equivalent lubricant meeting GM specification 9985830 (RWD w/4-speed Automatic Transmission). 2. Install the propeller shaft into the transmission or transfer case. Align the reference marks made during removal. 3. Install the propeller shaft (3) to the rear axle pinion yoke (4). Align the reference marks made during removal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the yoke retainers (2) and bolts (1) and tighten to 25 Nm (18 lb ft). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7892 Drive/Propeller Shaft: Service and Repair One-Piece Propeller Shaft Replacement One-Piece Propeller Shaft Replacement Removal Procedure Note: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reference mark the propeller shaft (1), the universal joint strap (2), universal bearing cap (4), the drive pinion yoke (5), and the rear axle housing (6). 3. Remove the bolts (3) and the universal straps (2) from the rear axle pinion yoke (5). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 4. Remove the propeller shaft from the rear axle pinion yoke. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7893 5. Reference mark the transmission or the transfer case (1), propeller shaft flip yoke (2), universal joint bearing cap (3), and the propeller shaft (4). 6. Remove the propeller shaft from the vehicle. Installation Procedure 1. Inspect the splines of the slip yoke for a sufficient coating of grease. If the splines of the slip yoke does not have a sufficient coating of grease, lubricate the shaft with clean grease or transmission fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7894 2. Align the reference marks on the propeller shaft (4), the slip yoke (2), the universal bearing caps (3), the transmission or the transfer case (1). 3. Install the propeller shaft in the transmission or transfer the case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7895 Note: Ensure that the reference marks are aligned before installing the propeller shaft. 4. Align the reference marks on the propeller shaft (1), universal bearing cap (4), pinion flange (5), and the rear axle housing (6). 5. With the reference marks aligned, install the propeller shaft (1) on the rear axle (6). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the rear propeller shaft bolts (3) and the strap (2). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 7. Remove the support and lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7896 Drive/Propeller Shaft: Service and Repair Two-Piece Propeller Shaft Replacement Two-Piece Propeller Shaft Replacement Special Tools J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Note: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reference mark the propeller shaft (1), the universal joint strap (2), the universal bearing cap (4), the drive pinion yoke (5), and the rear axle housing (6). 3. Remove the rear propeller shaft bolts (3) and the universal joint strap (2). 4. Using a flat bladed tool, remove the clamp (2) securing the boot (3) to the front propeller slip yoke (4) and at the center bearing (1) by prying up the exposed end of the clamp (2). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7897 joint. 5. Remove the rear propeller shaft from the rear axle and the center support bearing. Note: Step 6 is for those vehicles that have a slip yoke from the transmission from transfer case to the propeller shaft. 6. Reference mark the transmission or the transfer case (1), propeller shaft slip yoke (2), universal bearing cap (3), and the propeller shaft (4). Note: Step 7 is for those vehicles that have the yoke attached to the output shaft. 7. Reference mark the transmission or transfer case (1), output shaft flange (2), universal joint bearing cap (3), and the propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7898 8. Remove the center bearing support nuts (1). 9. Remove the center bearing support (2). Note: For those vehicles equipped with the yoke attached to the output shaft, proceed to step 10. Those vehicles equipped with a slip yoke, proceed to step 12. 10. For vehicles equipped with the yoke attached to the output shaft, use a suitable jack stand support the propeller shaft until propeller shaft is to be removed. 11. Remove the propeller shaft bolts (3), the straps (4), and the propeller shaft (2) from the transmission or the transfer case (1). 12. Remove the propeller shaft from the transmission or the transfer case. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7899 Note: If servicing a propeller shaft with a slip yoke, proceed to step 1. If servicing a propeller shaft with the yoke attached to the output shaft of the transmission or the transfer case, proceed to step 3. 1. Align the reference marks on the transmission or the transfer case (1), slip yoke (2), universal bearing cap (3), and the propeller shaft. 2. Install the propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7900 3. Align the reference marks on the transmission or the transfer case (1), output shaft yoke (2), and the propeller shaft (6). Note: When installing the propeller shaft bolts, hand tighten the bolts. DO NOT tighten them to specification until the center bearing support bolts have been installed and torqued to specifications. 4. Install the propeller shaft (2), the straps (3), the propeller shaft bolts (3) on the transmission or the transfer case (1). 5. Position the center support bearing (1) on the frame. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7901 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the center bearing support nuts. Tighten the center support bearing nuts to 40 Nm (30 lb ft). 7. Tighten the propeller shaft bolts (3) to specifications. Tighten the propeller shaft bolts to 25 Nm (18 lb ft). 8. Install the boot (3) and the new clamps (2) onto the front propeller shaft slip yoke (4). Note: Ensure that the master splines on the slip yoke and the stub shaft are aligned before installing the rear propeller shaft. 9. Apply a small amount of clean chassis grease to the slip yoke and the rear propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7902 10. Install the rear portion of the propeller into the front portion of the propeller shaft. 11. Align the reference marks on the rear axle housing (6), pinion yoke (5), universal bearing cap (4), and the rear propeller shaft (1). 12. Install the straps (2) and the bolts (3). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 13. Using the J 43218 , crimp the boot clamps until the dimensions shown are obtained. 14. Remove the support and lower that vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7903 Drive/Propeller Shaft: Service and Repair Front Propeller Shaft Replacement Front Propeller Shaft Replacement Special Tools J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Note: Before disassembly, observe and accurately reference mark all driveline components relative to the propeller shaft and axles. These items include the following components: * The propeller shafts * The wheel drive shafts * The pinion flanges * The output shafts Assemble all components in the exact relationship to each other as they were prior to removal. Observe all published specifications and torque values, and any measurements obtained prior to disassembly. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the clamp (4) at the transfer case by prying up the exposed end of the clamp with a flat-bladed tool. 3. Reference mark the relationship of the propeller shaft to the front axle pinon yoke. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7904 Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 4. Remove the bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). Note: Do not drop the bearing cap assemblies of the yoke end. 5. Disconnect the propeller shaft (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. 6. Use tape to secure the bearing caps. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7905 7. Remove the boot from the groove on the transfer case output shaft. 8. Remove the propeller shaft from the transfer case output shaft by sliding the propeller shaft forward. 9. Remove the clamp (1) from the propeller shaft boot (2), if needed. 10. Remove the propeller shaft boot (2) from the propeller shaft, if needed. Installation Procedure 1. Inspect the splines of the transfer case output shaft for a sufficient coating of lubricant. If the output shaft does not have a sufficient coating of lubricant, lubricate the shaft with grease, GM P/N 12345879 (Canadian P/N 10953511), or equivalent lubricant meeting GM Specification 9985830. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7906 2. Install the propeller shaft boot (2). 3. Install the propeller shaft boot clamp (1). 4. Install the propeller shaft splines into the transfer case output shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7907 5. Install the propeller shaft (5) to the front axle pinion yoke (1). Align the reference marks made during removal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the yoke retainers (7) and the bolts (6). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 7. Install the boot onto the transfer case output shaft until the boot snaps into the groove on the output shaft. 8. Using the J 43218 to crimp both clamps. 9. Lower the vehicle. Rear Propeller Shaft Replacement Rear Propeller Shaft Replacement Removal Procedure Note: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reference mark the propeller shaft to the rear axle pinion yoke. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7908 3. Reference mark the propeller shaft to the transmission or transfer case. 4. Remove the bolts (1) and the yoke retainers (2) from the rear axle pinion yoke (3). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 5. Slide the propeller shaft forward in order to disconnect the propeller shaft from the rear axle pinion yoke. 6. Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transmission or transfer case. 7. Remove the propeller shaft from the vehicle. Installation Procedure 1. Inspect the splines of the slip yoke for a sufficient coating of lubricant. If the splines of the slip yoke do not have a sufficient coating of lubricant, lubricate the shaft with lubricant GM P/N 12345879 (Canadian P/N 10953511) or with an equivalent lubricant meeting GM specification 9985830 (RWD w/4-speed Automatic Transmission). 2. Install the propeller shaft into the transmission or transfer case. Align the reference marks made during removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7909 3. Install the propeller shaft (3) to the rear axle pinion yoke (4). Align the reference marks made during removal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the yoke retainers (2) and bolts (1) and tighten to 25 Nm (18 lb ft). 5. Lower the vehicle. One-Piece Propeller Shaft Replacement One-Piece Propeller Shaft Replacement Removal Procedure Note: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reference mark the propeller shaft (1), the universal joint strap (2), universal bearing cap (4), the drive pinion yoke (5), and the rear axle housing (6). 3. Remove the bolts (3) and the universal straps (2) from the rear axle pinion yoke (5). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7910 joint. 4. Remove the propeller shaft from the rear axle pinion yoke. 5. Reference mark the transmission or the transfer case (1), propeller shaft flip yoke (2), universal joint bearing cap (3), and the propeller shaft (4). 6. Remove the propeller shaft from the vehicle. Installation Procedure 1. Inspect the splines of the slip yoke for a sufficient coating of grease. If the splines of the slip yoke does not have a sufficient coating of grease, lubricate the shaft with clean grease or transmission fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7911 2. Align the reference marks on the propeller shaft (4), the slip yoke (2), the universal bearing caps (3), the transmission or the transfer case (1). 3. Install the propeller shaft in the transmission or transfer the case. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7912 Note: Ensure that the reference marks are aligned before installing the propeller shaft. 4. Align the reference marks on the propeller shaft (1), universal bearing cap (4), pinion flange (5), and the rear axle housing (6). 5. With the reference marks aligned, install the propeller shaft (1) on the rear axle (6). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the rear propeller shaft bolts (3) and the strap (2). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 7. Remove the support and lower the vehicle. Two-Piece Propeller Shaft Replacement Two-Piece Propeller Shaft Replacement Special Tools J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Note: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reference mark the propeller shaft (1), the universal joint strap (2), the universal bearing cap (4), the drive pinion yoke (5), and the rear axle housing (6). 3. Remove the rear propeller shaft bolts (3) and the universal joint strap (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7913 4. Using a flat bladed tool, remove the clamp (2) securing the boot (3) to the front propeller slip yoke (4) and at the center bearing (1) by prying up the exposed end of the clamp (2). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 5. Remove the rear propeller shaft from the rear axle and the center support bearing. Note: Step 6 is for those vehicles that have a slip yoke from the transmission from transfer case to the propeller shaft. 6. Reference mark the transmission or the transfer case (1), propeller shaft slip yoke (2), universal bearing cap (3), and the propeller shaft (4). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7914 Note: Step 7 is for those vehicles that have the yoke attached to the output shaft. 7. Reference mark the transmission or transfer case (1), output shaft flange (2), universal joint bearing cap (3), and the propeller shaft. 8. Remove the center bearing support nuts (1). 9. Remove the center bearing support (2). Note: For those vehicles equipped with the yoke attached to the output shaft, proceed to step 10. Those vehicles equipped with a slip yoke, proceed to step 12. 10. For vehicles equipped with the yoke attached to the output shaft, use a suitable jack stand support the propeller shaft until propeller shaft is to be removed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7915 11. Remove the propeller shaft bolts (3), the straps (4), and the propeller shaft (2) from the transmission or the transfer case (1). 12. Remove the propeller shaft from the transmission or the transfer case. Installation Procedure Note: If servicing a propeller shaft with a slip yoke, proceed to step 1. If servicing a propeller shaft with the yoke attached to the output shaft of the transmission or the transfer case, proceed to step 3. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7916 1. Align the reference marks on the transmission or the transfer case (1), slip yoke (2), universal bearing cap (3), and the propeller shaft. 2. Install the propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7917 3. Align the reference marks on the transmission or the transfer case (1), output shaft yoke (2), and the propeller shaft (6). Note: When installing the propeller shaft bolts, hand tighten the bolts. DO NOT tighten them to specification until the center bearing support bolts have been installed and torqued to specifications. 4. Install the propeller shaft (2), the straps (3), the propeller shaft bolts (3) on the transmission or the transfer case (1). 5. Position the center support bearing (1) on the frame. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the center bearing support nuts. Tighten the center support bearing nuts to 40 Nm (30 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7918 7. Tighten the propeller shaft bolts (3) to specifications. Tighten the propeller shaft bolts to 25 Nm (18 lb ft). 8. Install the boot (3) and the new clamps (2) onto the front propeller shaft slip yoke (4). Note: Ensure that the master splines on the slip yoke and the stub shaft are aligned before installing the rear propeller shaft. 9. Apply a small amount of clean chassis grease to the slip yoke and the rear propeller shaft. 10. Install the rear portion of the propeller into the front portion of the propeller shaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7919 11. Align the reference marks on the rear axle housing (6), pinion yoke (5), universal bearing cap (4), and the rear propeller shaft (1). 12. Install the straps (2) and the bolts (3). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 13. Using the J 43218 , crimp the boot clamps until the dimensions shown are obtained. 14. Remove the support and lower that vehicle. Propeller Shaft Slip Yoke Boot Replacement Propeller Shaft Slip Yoke Boot Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 7920 Propeller Shaft Slip Yoke Replacement Propeller Shaft Slip Yoke Replacement To replace the propeller shaft slip yoke, refer to Universal Joint Replacement (See: Universal Joint/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 7921 Drive/Propeller Shaft: Tools and Equipment Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair Universal Joint: Service and Repair Universal Joint Replacement Special Tools * J-9522-3 - U-Joint Bearing Separator * J-9522-5 - U-Joint Bearing Spacer Remover Removal Procedure Caution: Never clamp propeller shaft tubing in a vise. Clamping propeller shaft tubing in a vise could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. Note: The following service procedure can be used for either the external retaining ring or the nylon injected ring. Note: If replacing the propeller shaft slip yoke, proceed to step 10. 1. Using a hammer (2), tap the yoke (1) lightly in order to relieve the pressure from the universal joint retaining ring. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 7925 2. Using a pair of pliers, remove the retaining ring (2) from the yoke (1). 3. With the aide of an assistant, support the propeller shaft so that it level with the press. 4. Using the appropriate size socket (2), support the universal joint opposite of the J-9522-3 U-Joint Bearing Separator. 5. Using the J-9522-3 - Separator (1) and the press, remove the universal bearing from the yoke. 6. If you are unable to completely remove the universal bearing with the J-9522-3 - Separator , proceed to step 7. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 7926 7. Position the J-9522-5 - U-Joint Bearing Spacer Remover (1) on the universal joint. Note: The following procedure is also used for the breaking of the nylon injected ring for those universal joints that are equipped. 8. Using the J-9522-3 - Separator , J-9522-5 - Remover and a press, remove the universal bearing from the yoke. 9. Rotate the propeller shaft and repeat steps 1-8 to remove the opposite universal joint. Note: If the slip yoke is found to be damaged, replace the slip yoke and use a NEW universal joint. DO NOT re-use the old universal joint. 10. Remove the slip yoke (1) from the propeller shaft (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 7927 11. Remove the retaining ring (1) from the slip yoke (3). 12. Using the J-9522-3 - Separator , J-9522-5 - Remover and a press, remove the universal bearing (2) from the yoke (3). 13. Remove the spider (2) from the slip yoke (1). 14. Thoroughly clean the slip yoke and the propeller shaft yoke of any contaminates that could prevent the retaining rings or the bearing cups from being properly installed. Installation Procedure Note: If replacing the propeller shaft slip yoke, proceed to step 8. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 7928 1. Position the universal bearings in either side of the yoke on the propeller shaft. 2. Install the universal joint spider until it is seated in the universal bearing. 3. Press the universal joint spider until the bearing is even with the yoke. 4. Install the retaining ring (1) in the yoke (2). 5. Rotate the propeller shaft and repeat steps 1-4 for the opposite universal bearing. 6. Rotate the universal joint to ensure that the universal joint moves freely. If not, use a hammer and lightly tap the yoke to seat the universal bearing against the retaining ring. 7. Install the other two universal bearings and wrap them with electrical tape or equivalent to hold the bearing in place until the propeller shaft is installed in the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 7929 8. Position the universal spider (2) in the slip yoke (1). 9. Install the universal bearings (2) in either side of the slip yoke (2). 10. Fully seat one of the universal spiders in the universal bearing. 11. Press the universal bearings (2) into the slip yoke (2) until it is even with the yoke. 12. Install the retaining ring (1) in the slip yoke (3). 13. Rotate the slip yoke and repeat steps 3-5 for the opposite universal bearing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 7930 14. Position the slip yoke (1) in the propeller shaft (2). 15. Position the universal bearing (1) in the yoke of the propeller shaft (2). 16. Center the universal spider in the universal bearing. 17. Press the universal bearing into the yoke. 18. Install the retaining ring (2) in the propeller shaft yoke (1). 19. Rotate the propeller shaft and repeat steps 8-11 or the opposite universal bearing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 7931 20. Rotate the universal joint to ensure that the universal joint moves freely. If not, use a hammer (2) and lightly tap each of the yokes (1) to seat the universal bearing against the retaining ring. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Automatic Transmission Flex Plate Bolts - First Pass....................................................................................................................................20 Nm (15 lb ft.) Automatic Transmission Flex Plate Bolts - Second Pass...............................................................................................................................50 Nm (37 lb ft.) Automatic Transmission Flex Plate Bolts - Final Pass.................................................................................................................................100 Nm (74 lb ft.) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement Flex Plate: Service and Repair Engine Flywheel Replacement Engine Flywheel Replacement Special Tools * J 44643 Flywheel Holding Tool * J 45059 Angle Meter Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L60-E /4L65-E/4L70-E transmission, Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L50/4L80/4L90 transmission, or Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the Allison transmission. 2. Install J 44643 in order to hold the flywheel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement > Page 7937 Warning When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury. 3. Remove and discard the flywheel bolts. 4. Remove the flywheel washer and flywheel. Installation Procedure Warning When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury. Note: When installing the flywheel, ensure that the tapered side of the teeth are facing the starter. 1. Install the flywheel. 2. Install the flywheel washer with the beveled side facing the engine. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Caution: This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage. 3. Install NEW flywheel bolts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement > Page 7938 4. Tighten the flywheel bolts in the proper sequence. 1. Tighten the bolts a first pass to 79 Nm (58 lb ft). 2. Tighten the bolts a second pass to 60 degrees using J 45059 . 3. Tighten the bolts a final pass an additional 60 degrees using J 45059 . 5. Remove J 44643 from the flywheel. 6. Install the transmission. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L60-E/4L65-E/4L70-E transmission, Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L50/4L80/4L90 transmission, or Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the Allison transmission. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement > Page 7939 Flex Plate: Service and Repair Automatic Transmission Flex Plate Replacement Automatic Transmission Flex Plate Replacement Removal Procedure 1. Remove the automatic transmission. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L60-E. Note: Note the position and direction of the engine flywheel before removal. 2. Remove the flywheel bolts. 3. Remove the flywheel. 4. Install two M11x1.5 mm bolts (1) to the threaded holes of the spacer, if applicable. 5. Rotate the bolts clockwise to remove the spacer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement > Page 7940 6. Remove the spacer from the rear of the crankshaft, if applicable. Installation Procedure Note: * The flywheel does not use a locating pin for alignment and will not initially seat against the crankshaft flange or spacer, if applicable, but will be pulled onto the crankshaft by the engine flywheel bolts. This procedure requires a three stage tightening process. * Certain applications (6.0L) require a spacer and longer bolts for proper flywheel position. 1. Install the spacer, if applicable, onto the rear of the crankshaft. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement > Page 7941 Note: Longer flywheel bolts must be used on applications using a flywheel spacer. 2. Install the flywheel and bolts to the crankshaft. 3. Apply threadlock to the threads of the flywheel bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the flywheel bolts. * Tighten the bolts (1-6) a first pass in sequence to 20 Nm (15 lb ft). * Tighten the bolts (1-6) a second pass in sequence to 50 Nm (37 lb ft). * Tighten the bolts (1-6) a final pass in sequence to 100 Nm (74 lb ft). 5. Install the automatic transmission. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L60-E. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel Bolts First pass in sequence ......................................................................................................................... .......................................................... 20 Nm (15 lb ft) Second pass in sequence ............................... ............................................................................................................................................... 50 Nm (37 lb ft) Final pass in sequence .......................................................................................................... ...................................................................... 100 Nm (74 lb ft) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 7945 Flywheel: Service and Repair Engine Flywheel Installation Note: * For manual transmission applications, note the position and direction of the engine flywheel before removal. Mark or scribe the end of the crankshaft and flywheel before component removal. The existing manual transmission engine flywheel must be installed to the original position and direction. * The flywheel does not use a locating pin for alignment and will not initially seat against the crankshaft flange, but will be pulled onto the crankshaft by the engine flywheel bolts. This procedure requires a 3 stage tightening process. 1. Install the manual transmission flywheel to the crankshaft, in the original position and direction. 2. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolts. 1. Tighten the bolts (1-6) a first pass in sequence to 20 Nm (15 lb ft). 2. Tighten the bolts (1-6) a second pass in sequence to 50 Nm (37 lb ft). 3. Tighten the bolts (1-6) a final pass in sequence to 100 Nm (74 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair Bell Housing: Service and Repair Flywheel Housing Replacement Special Tools J 37228 Seal Cutter Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Remove the crankshaft rear oil seal. Refer to Crankshaft Rear Oil Seal Replacement (See: Engine, Cooling and Exhaust/Engine/Seals and Gaskets/Crankshaft Main Bearing Seal/Service and Repair). 3. Remove the turbocharger oil return pipe nuts from the top of the flywheel housing. 4. Remove the oil cooler adapter studs and nuts from the flywheel housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair > Page 7950 5. Remove the upper oil pan. Refer to Upper Oil Pan Replacement (). 6. Remove the oil filter. 7. Remove the flywheel housing bolts, denoted by the black circles. 8. Separate the flywheel from the cylinder block using J 37228 . 9. Remove the flywheel housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair > Page 7951 10. Remove the turbocharger oil return pipe gasket from the flywheel housing. 11. Remove the oil cooler adapter bolts. 12. Remove the oil cooler adapter and gaskets. 13. If required, clean and inspect the flywheel housing. Refer to Flywheel Housing Cleaning and Inspection (). Installation Procedure 1. Install NEW O-ring seals to the flywheel housing, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair > Page 7952 2. Apply a 2 mm (1/8 in) wide bead of sealant (3) to the flywheel housing sealing surfaces. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. 3. Install a NEW oil cooler adapter gasket. 4. Install a NEW oil cooler adapter to flywheel housing gasket. 5. Install the oil cooler adapter to the flywheel housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the oil cooler adapter bolts. Tighten the bolts/nuts to 21 Nm (15 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair > Page 7953 7. Install the flywheel housing bolts, denoted by the black circles. Tighten the bolts to 90 Nm (67 lb ft). 8. Install the oil cooler adapter studs and nuts to the flywheel housing. * Tighten the oil cooler adapter studs to 10 Nm (89 lb in). * Tighten the oil cooler adapter nuts to 25 Nm (18 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair > Page 7954 9. Install the oil filter. 10. Install the upper oil pan. Refer to Upper Oil Pan Replacement (). 11. Install a NEW gasket to the turbocharger oil return pipe. 12. Install the turbocharger oil return pipe to flywheel housing nuts. Tighten the nuts to 21 Nm (15 lb ft). 13. Install the crankshaft rear oil seal. Refer to Crankshaft Rear Oil Seal Replacement (See: Engine, Cooling and Exhaust/Engine/Seals and Gaskets/Crankshaft Main Bearing Seal/Service and Repair). 14. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Fluid - M/T: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Fluid - M/T: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 7974 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Fluid - M/T: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 7975 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Fluid - M/T: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 7981 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Fluid - M/T: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 7982 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications MANUAL TRANSMISSION FLUID CAPACITY TREMEC 5-SPEED (RPO M96) .......................................................................................................................................................... 3.5 liters (3.7 quarts) TREMEC 5-SPEED (RPO TZ0) .......................................................................................................................................................... 4.4 liters (4.6 quarts) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 7987 Fluid - M/T: Fluid Type Specifications MANUAL TRANSMISSION FLUID TYPE TREMEC 5-SPEED (M96) ............................................................................................................................................. 5W-30 Synthetic Oil P/N ET-M99 TREMEC 5-SPEED (TZ0) .............................................................................................................................................. 1874 MTX Fluid 12550 ET-M81 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission Fluid - M/T: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 3. Remove the oil fill plug (1). 4. Remove the oil drain plug (2). 5. Remove any old sealant from the transmission housing. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 7990 1. Apply a thin bead of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain plug threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the oil drain plug (2). Tighten the plug to 37 Nm (27 lb ft). 3. Fill the transmission with the proper fluid to just below the bottom of the fill plug hole. 4. Apply a thin bead of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil fill plug threads. 5. Install the oil fill plug (1). Tighten the plug to 37 Nm (27 lb ft). 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 7991 Fluid - M/T: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Transmission Fluid Replacement Special Tools J 36511 Oil Fill/Drain Plug Hex Bit (17 mm) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Using J 36511 remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Using J 36511 remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 7992 Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Using J 36511 install the oil drain plug. Tighten the plug to 30 Nm (22 lb ft). 3. Remove and drain the drain pan used to catch the used transmission fluid. 4. Fill the transmission to just below the bottom of the fill plug hole. Refer to Lubrication Specifications (See: Specifications/Mechanical Specifications/Tremec 5-Speed (TZ0) - Manual Transmission/Lubrication Specifications). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 7993 5. Using J 36511 install the oil fill plug. Tighten the plug to 30 Nm (22 lb ft). 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair Seals and Gaskets: Service and Repair Main Shaft Rear Seal Replacement Tools Required * J 23129 Universal Seal Remover * J 6125-1B Slide Hammer * J 36503 Extension Housing Seal Installer Removal Procedure 1. Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 2. Remove the rear oil seal using J 6125-1B (1) and J 23129 (2). Installation Procedure 1. Using J 36503 install the NEW rear oil seal. 2. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 3. Check to transmission fluid level. Add if necessary. 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection Clutch Pedal Position Sensor Learn Important: The clutch pedal position (CPP) sensor learn procedure is required when the following service procedures have been performed regardless of whether DTC P080A is set: * An engine control module (ECM) replacement * A CPP sensor replacement * Any repairs which affect the CPP sensor relationship 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P080A, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select Clutch Pedal Position Learn under Module Setup in Manual Transmission, and perform the following instructions displayed on the scan tool screen. Important: The CPP sensor learn procedure cannot be performed more than once per ignition cycle. The clutch pedal needs to be fully depressed and held steady throughout this procedure in order to perform a correct learning. 4. The scan tool will display under CPP Learn Status: Not Learned, In Process, Complete, Fail Low Volt, Fail - High Volt, or Fail Moving. The scan tool will display under CPP Learn Status Complete if the process was successful. 5. If the scan tool indicates that DTC P080A ran and passed this ignition the CPP sensor learn procedure is complete. If the scan tool indicates DTC P080A failed or did not run this ignition, refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission). If any other DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC. 6. Turn OFF the ignition for 30 seconds after the learn procedure has successfully completed in order to store the CPP sensor variation values in ECM history. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 8001 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Engine Start Switch Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Remove the plastic retainer (1) tabs from the clutch pedal position switch (2). 3. Remove the clutch pedal position switch (2) from the pushrod. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 8002 1. Install the clutch pedal position switch (2) to the pushrod. 2. Install the plastic retainer (1) tabs to the clutch pedal position switch (2). 3. Connect the clutch pedal position switch electrical connector (1). Warning Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged. 4. Perform the clutch pedal position sensor learn procedure. Refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission) or Clutch Pedal Position Sensor Learn (See: Testing and Inspection/Component Tests and General Diagnostics). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission Shifter M/T: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Transmission Control Replacement Transmission Control Replacement Transmission Control Lever Boot Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8007 Transmission Control Lever Boot Replacement Removal Procedure 1. Remove the transmission control lever. Refer to Transmission Control Lever Knob Replacement (See: Transmission Control Lever Knob Replacement). 2. Lift and push the lower edge of the control lever boot as necessary in order to expose the retaining screws 3. Remove the 4 control lever boot retaining screws (2). 4. Carefully release the 4 plastic retainers (3) from the floor and remove the control lever boot retaining bezel (1), boot (4), and retainers (3) as an assembly. 5. Remove the 4 plastic retainers (3) in order to separate the control lever boot retaining bezel (1) from the boot (4). 6. Remove the control lever insulator (5) from the floor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8008 1. Install the control lever insulator (5) to the floor. 2. Assemble the control lever boot retaining bezel (1) to the boot (4) and insert the 4 plastic retainers (3). 3. Install the control lever boot retaining bezel (1), boot (4) and secure the 4 plastic retainers (3) to the floor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Lift and push the lower edge of the control lever boot as necessary in order to install the 4 retaining screws (2). Tighten the screws to 1.6 Nm (14 lb in). 5. Install the transmission control lever. Refer to Transmission Control Lever Knob Replacement (See: Transmission Control Lever Knob Replacement). Transmission Control Lever Knob Replacement Transmission Control Lever Knob Replacement Removal Procedure 1. Remove the control lever boot from the control lever. Note: DO NOT move the shift lever assembly adjustment nut if replacing the control lever. 2. Remove the control lever. Installation Procedure 1. Install the control lever. 2. If alignment of the control lever is necessary, or if the shift lever assembly was replaced perform the following: 1. The nut must be seated at the bottom of the thread runout on the shift lever. 2. Seat the control lever against the shift lever assembly adjustment nut. 3. Back the control lever off the nut in order to align the index mark on the control lever perpendicular to the edge of the control lever boot retainer. 4. Ensure that the index mark is located on the passenger side and that the shift pattern is aligned parallel to the vehicle centerline or rotated no more than 6 degrees clockwise. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Hold the control lever and tighten the shift lever assembly nut against the control lever. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8009 Tighten the nut to 37 Nm (27 lb in). 6. Install the control lever boot to the control lever. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8010 Shifter M/T: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Transmission Control Lever Boot Replacement Transmission Control Lever Boot Replacement Removal Procedure 1. Remove the transmission control lever. Refer to Transmission Control Lever Knob Replacement (See: Tremec 5-Speed (M96) - Manual Transmission/Transmission Control Lever Knob Replacement). 2. Lift and push the lower edge of the control lever boot as necessary in order to expose the retaining screws 3. Remove the 4 control lever boot retaining screws (2). 4. Carefully release the 4 plastic retainers (3) from the floor and remove the control lever boot retaining bezel (1), boot (4), and retainers (3) as an assembly. 5. Remove the 4 plastic retainers (3) in order to separate the control lever boot retaining bezel (1) from the boot (4). 6. Remove the control lever insulator (5) from the floor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8011 1. Install the control lever insulator (5) to the floor. 2. Assemble the control lever boot retaining bezel (1) to the boot (4) and insert the 4 plastic retainers (3). 3. Install the control lever boot retaining bezel (1), boot (4) and secure the 4 plastic retainers (3) to the floor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Lift and push the lower edge of the control lever boot as necessary in order to install the 4 retaining screws (2). Tighten the screws to 1.6 Nm (14 lb in). 5. Install the transmission control lever. Refer to Transmission Control Lever Knob Replacement (See: Tremec 5-Speed (M96) - Manual Transmission/Transmission Control Lever Knob Replacement). Transmission Control Lever Knob Replacement Transmission Control Lever Knob Replacement Removal Procedure 1. Remove the control lever boot from the control lever. Note: DO NOT move the shift lever assembly adjustment nut if replacing the control lever. 2. Remove the control lever. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8012 1. Install the control lever. 2. If alignment of the control lever is necessary, or if the shift lever assembly was replaced perform the following: 1. The nut must be seated at the bottom of the thread runout on the shift lever. 2. Seat the control lever against the shift lever assembly adjustment nut. 3. Back the control lever off the nut in order to align the index mark on the control lever perpendicular to the edge of the control lever boot retainer. 4. Ensure that the index mark is located on the passenger side and that the shift pattern is aligned parallel to the vehicle centerline or rotated no more than 6 degrees clockwise. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Hold the control lever and tighten the shift lever assembly nut against the control lever. Tighten the nut to 37 Nm (27 lb in). 6. Install the control lever boot to the control lever. Transmission Control Replacement Transmission Control Replacement Removal Procedure Note: * Ensure that the control lever is positioned into the mechanical third or fourth gear prior to removal of the shift lever from the transmission. The transmission must remain in this state when the shift lever is removed. * Do not disassemble the transmission shift lever. Internal parts for this shift lever are not available. Opening the shift lever voids the warranty. * When removing the shift lever from the transmission, use the exposed bolts on the base of the lever. 1. Remove the control lever and boot. Refer to Transmission Control Lever Boot Replacement (See: Tremec 5-Speed (M96) - Manual Transmission/Transmission Control Lever Boot Replacement). 2. Remove the boot. 3. Remove the shift lever bolts. 4. Remove the shift lever and seal. 5. Remove the shift lever insulator. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8013 1. Install a NEW shift lever insulator. 2. Install the shift lever seal and lever. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the shift lever bolts. Tighten the bolts to 20 Nm (15 lb ft). 4. Install the boot. 5. Install the control lever and boot. Refer to Transmission Control Lever Boot Replacement (See: Tremec 5-Speed (M96) - Manual Transmission/Transmission Control Lever Boot Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair Transmission Mount: Service and Repair Transmission Rear Mount Replacement Removal Procedure Caution: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission mount to crossmember nut (1). 3. Remove the transmission mount to transmission bolts. 4. Raise the transmission just enough in order to permit removal of the mount using a suitable transmission jack. 5. Remove the transmission mount. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Page 8017 1. Position the transmission mount. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission mount to transmission bolts. Tighten the bolts to 50 Nm (37 lb ft). 3. Lower the transmission and remove the transmission jack. 4. Install the transmission mount to crossmember nut (1). Tighten the nut to 40 Nm (30 lb ft). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Power Take-Off Relay > Component Information > Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Power Take-Off Switch > Component Information > Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Relays and Modules - Power Take-Off > Power Take-Off Relay > Component Information > Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8043 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8044 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8045 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8051 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8052 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8053 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8059 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8060 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8061 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8067 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8068 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8069 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8070 Control Module: Locations Harness Routing Views Engine Chassis Harness Routing - Top Front (Diesel) 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8071 Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8072 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8073 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8074 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8075 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Power Take-Off > Power Take-Off Relay > Component Information > Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF or NQH) Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8084 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8085 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8088 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8102 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8103 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8104 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8110 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8111 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8112 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 8113 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Parking Lock and Manual Shift Detent Lever with Shaft Position Switch Assembly 78 - Steel Cup Plug 79 - Parking Brake Pawl Shaft 80 - Parking Pawl Return Spring 81 - Parking Brake Pawl 82 - Manual Shaft Seal 84 - Manual Shaft - Model Dependent 85 - Parking Lock Actuator Assembly 86 - Parking Lock Bracket 87 - Parking Lock Bracket Bolt 88 - Manual Shift Detent Lever with Shaft Position Switch Assembly 89 - Manual Valve Link 92 - Manual Shift Detent Lever Hub Pin Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8118 Transmission Position Switch/Sensor: Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 8119 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8122 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8123 Transmission Position Switch/Sensor: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 Nm (9 lb ft). 3. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Install the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8124 Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Speed Sensor: Component Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 8129 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Oil Pump Assembly 200 - Pump Body 201 - Oil Seal Ring - Slide to Wear Plate 202 - O-Ring Seal - Slide Seal Back-Up 203 - Pump Slide 204 - Pivot Pin Spring 205 - Pivot Slide Pin 208 - Pump Slide Seal Support 209 Pump Slide Seal 210 - Pump Vane Ring 210 - Pump Vane Ring 211 - Rotor Guide 212 - Oil Pump Rotor 213 - Pump Vane 214 - Stator Shaft 215 - Pump Cover 216 - Pressure Regulator Valve Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 8130 217 - Pressure Regulator Valve Spring 218 - Pressure Regulator Isolator Spring 219 - Reverse Boost Valve 220 - Reverse Boost Valve Sleeve 221 - Oil Pump Reverse Boost Valve Retaining Ring 222 - Oil Pump Converter Clutch Valve Retaining Ring 223 - Stop Valve 224 - Converter Clutch Valve - Model Dependent 227 - Pressure Relief Bolt Rivet 228 - Pressure Relief Ball 229 Pressure Relief Spring 230 - Oil Seal Ring - Stator Shaft 231 - Oil Pump Cover Screen Seal 232 Oil Pump Cover Screen 233 - Bolt M8 X 1.25 X 40 - Cover to Body 234 - Stator Shaft Bushing Front 235 - Oil Pump Cover Plug - FWD Clutch Feed 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 237 - Check Valve Retainer and Ball Assembly 237 - Check Valve Retainer and Ball Assembly 238 - Converter Clutch Signal Orifice - Cup Plug 240 - Cup Orifice Plug 241 Stator Shaft Bushing - Rear 242 - Pump Body Bushing 243 - Oil Seal Assembly 244 - Fluid Seal Retainer 245 - A/T Fluid Pump Slide Outer Spring 246 - Converter Clutch Valve Spring 247 - A/T ISS Attaching Bolt - Model Dependent 249 - O-ring 250 - A/T Input Speed Sensor (ISS) Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 8131 Transmission Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8132 Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8133 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8134 Transmission Speed Sensor: Service and Repair Input and Output Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 8138 Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection Clutch Pedal Position Sensor Learn Important: The clutch pedal position (CPP) sensor learn procedure is required when the following service procedures have been performed regardless of whether DTC P080A is set: * An engine control module (ECM) replacement * A CPP sensor replacement * Any repairs which affect the CPP sensor relationship 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P080A, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select Clutch Pedal Position Learn under Module Setup in Manual Transmission, and perform the following instructions displayed on the scan tool screen. Important: The CPP sensor learn procedure cannot be performed more than once per ignition cycle. The clutch pedal needs to be fully depressed and held steady throughout this procedure in order to perform a correct learning. 4. The scan tool will display under CPP Learn Status: Not Learned, In Process, Complete, Fail Low Volt, Fail - High Volt, or Fail Moving. The scan tool will display under CPP Learn Status Complete if the process was successful. 5. If the scan tool indicates that DTC P080A ran and passed this ignition the CPP sensor learn procedure is complete. If the scan tool indicates DTC P080A failed or did not run this ignition, refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission). If any other DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC. 6. Turn OFF the ignition for 30 seconds after the learn procedure has successfully completed in order to store the CPP sensor variation values in ECM history. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 8143 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Engine Start Switch Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Remove the plastic retainer (1) tabs from the clutch pedal position switch (2). 3. Remove the clutch pedal position switch (2) from the pushrod. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 8144 1. Install the clutch pedal position switch (2) to the pushrod. 2. Install the plastic retainer (1) tabs to the clutch pedal position switch (2). 3. Connect the clutch pedal position switch electrical connector (1). Warning Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged. 4. Perform the clutch pedal position sensor learn procedure. Refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission) or Clutch Pedal Position Sensor Learn (See: Manual Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Harness Routing Views Engine Harness Routing - Rear (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Dash Panel 2 - Transmission 3 - X175 (M30) 4 - Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8153 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF or NQH) Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8154 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8157 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8158 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8159 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Page 8166 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the speed sensor with a NEW O-ring. Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams Transfer Case Actuator: Diagrams Component Connector End Views Transfer Case Encoder Motor (NQF or NQH) Front Drive Axle Actuator (NQF, NQG or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8172 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Transfer Case Actuator: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8175 Transfer Case Actuator: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8176 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case Case Adapter: Service and Repair BW 4485-NR3 - Transfer Case Transfer Case Adapter Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8181 Case Adapter: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Transfer Case Adapter Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8182 Case Adapter: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Adapter Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8183 Case Adapter: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Adapter Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-04-19-002A > Feb > 11 > Drivetrain Excessive Effort When Shift 2HI to 4HI Case: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Case: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF or NQH) Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8200 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8201 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8204 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Fluid Transfer Case: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Fluid - Transfer Case: > 09-04-19-002A > Feb > 11 > Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications TRANSFER CASE FLUID BW 4485-NR3 ..................................................................................................................................... ...................................... Fill to bottom of drain hole. MP 1222/1225/1226-NQG ................................................................................................................... ............................................... 1.6 quarts (1.5 liters) MP 1625/1626-NQF ............................................................................................................................ ................................................ 1.6 quarts (1.5 liters) MP 3023/3024-NQH ............................................................................................................................ ............................................... 1.6 quarts (1.5 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 8223 Fluid - Transfer Case: Fluid Type Specifications TRANSFER CASE FLUID DEXRON-VI Automatic Transmission Fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case Fluid - Transfer Case: Service and Repair BW 4485-NR3 - Transfer Case Transfer Case Fluid Replacement Removal Procedure Note: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 3. Remove the fill plug. 4. Remove the drain plug. Note: Ensure that an approved drain pan is used when draining the transfer case. 5. Allow the transfer case to drain completely. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8226 Note: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the drain and fill plugs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the drain plug. Tighten the plug to 25 Nm (18 lb ft). 3. Fill the transfer case to the bottom of the fill plug hole with the recommended fluid. 4. Install the fill plug. Tighten the plug to 25 Nm (18 lb ft). 5. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 6. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8227 Fluid - Transfer Case: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Transfer Case Fluid Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8228 Fluid - Transfer Case: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Fluid Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8229 Fluid - Transfer Case: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Fluid Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Harness Routing Views Engine Harness Routing - Rear (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Dash Panel 2 - Transmission 3 - X175 (M30) 4 - Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8233 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF or NQH) Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8234 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8237 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8238 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8239 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF or NQH) Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8247 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8248 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8251 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case Seals and Gaskets: Service and Repair BW 4485-NR3 - Transfer Case Front Output Shaft Seal Replacement Front Output Shaft Seal Replacement Tools Required * J 8092 Driver Handle * J 43484 Output Shaft Seal Installer Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 3. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). Important: The front output shaft seal is a two piece internal seal. The inner seal race is a force fit on the front output shaft. 4. Remove the front output shaft seal by inserting a flat-tipped screwdriver behind the inner race of the seal. 5. Pry the inner seal race forward. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8256 6. Using a small pry bar, move the inner seal race forward on the front output shaft. 7. Remove the inner seal race from the front output shaft. 8. Insert a flat-tipped screwdriver or small pry bar into the space between the lip of the outer race of the seal and the transfer case. 9. Remove the remaining part of the output shaft seal from the transfer case. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8257 1. Install the J 43484 (2) to the J 8092 (1). 2. Install a NEW seal onto J 43484 . 3. Using J 43484 (2), and J 8092 (1), install the seal. 4. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 5. Check the fluid level. Add fluid, if necessary. 6. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 7. Lower the vehicle. Rear Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Tools Required J 45756 Output Shaft Seal Installer Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8258 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 3. Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 4. Remove the rear output shaft seal by prying it out with a flat tipped screwdriver. Installation Procedure 1. Using the J 45756 , install a NEW front output shaft seal. 2. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 3. Check the fluid level. Add fluid, if necessary. 4. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8259 5. Lower the vehicle. Input Shaft Seal Replacement Input Shaft Seal Replacement Tools Required * J 36825 Output Shaft Oil Seal Remover * J 23907 Slide Hammer with Bearing Adapter * J 42738 Front Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case. Refer to Transfer Case Assembly Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Assembly Replacement). Important: It may be necessary to use a sharp punch in order to poke a hole into the seal prior to inserting J 36825 . 2. Using the J 23907 (1), and J 36825 (2), remove the input seal. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8260 1. Using the J 42738 , install the input shaft seal. 2. Install the transfer case. Refer to Transfer Case Assembly Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 Transfer Case/Transfer Case Assembly Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8261 Seals and Gaskets: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Front Output Shaft Seal Replacement Front Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8262 Input Shaft Seal Replacement Input Shaft Seal Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8263 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8264 Seals and Gaskets: Service and Repair MP 1625/1626-NQF - Transfer Case Front Output Shaft Seal Replacement Front Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8265 Input Shaft Seal Replacement Input Shaft Seal Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8266 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8267 Seals and Gaskets: Service and Repair MP 3023/3024-NQH - Transfer Case Front Output Shaft Seal Replacement Front Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8268 Input Shaft Seal Replacement Input Shaft Seal Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8269 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Harness Routing Views Engine Harness Routing - Rear (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Dash Panel 2 - Transmission 3 - X175 (M30) 4 - Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8274 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF or NQH) Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8275 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8278 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8279 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8280 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Page 8287 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the speed sensor with a NEW O-ring. Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shift Fork, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Magna Transfer Case Service Parts Info. Shift Fork: Technical Service Bulletins Drivetrain - Magna Transfer Case Service Parts Info. INFORMATION Bulletin No.: 09-04-21-006 Date: October 29, 2009 Subject: Information on Magna Transfer Case Service Parts for Control Actuator Levers Models: 2007-2010 Cadillac Escalade Hybrid 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL All Equipped with Magna MP3023 Two-Speed Active Transfer Case (RPO NQH) or MP3010 Single-Speed Active Transfer Case (RPO NQH and NP0) Note Heavy duty (HD) components are the only parts available for service. The purpose of this bulletin is to provide information regarding the servicing of the Light Duty (LD) transfer cases. LD Transfer cases are built with LD control actuator levers (3 and 6) and are used with 13 mm (0.52 in) diameter control actuator lever balls (5). Heavy Duty (HD) components can be identified as using 10 mm (0.39 in) control actuator lever balls. Note Light Duty (LD) 2007-2010 MP3023-NQH and 2010 MP3010-NP0 transfer cases are built with LD control actuator levers (3 and 6) and are used with 13 mm (0.52 in) diameter control actuator lever balls (5). Heavy Duty (HD) components can be identified as using 10 mm (0.39 in) control actuator lever balls. Additional component dimensional information can be obtained within the applicable Transfer Case Description and Operation/Build Variations section of SI. When replacement of one or both of the LD control actuator levers is required, it is necessary to replace both of the levers and all three balls with the HD components as a set. It is also necessary to re-measure and adjust clutch pack clearances as required and to perform the Transfer Case High/Low Clutch Reset. Refer to Measuring/Adjusting Clutch Assembly Height in Transfer Case Assemble, Transfer Case Description and Operation and Transfer Case High/Low Clutch Reset. Refer to the table below for information regarding the HD design part numbers. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair Shifter Transfer Case: Service and Repair Transfer Case Control Lever Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shift Linkage, Transfer Case > Component Information > Service and Repair Shift Linkage: Service and Repair Transfer Case Control Rod Replacement Removal Procedure Note: Before beginning the following service procedure, place the transmission into the PARK position. Then place the transfer case in the 2 HI position. 1. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 2. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). Note: When performing this service procedure, use a small pocket screwdriver in order to release the retaining clip on the ends of the control rod. 3. Remove the control rod from the control lever. 4. Remove the control rod from the shift lever. 5. Remove the control rod. Installation Procedure Note: * Before installing a NEW control rod, loosen the adjusting bolt on the control rod so it slides with slight resistance. * When installing the control rod on the control levers, a snapping sound should be heard or felt upon installation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shift Linkage, Transfer Case > Component Information > Service and Repair > Page 8298 1. Install the control rod onto the control lever first. 2. Slide the control rod forward. 3. Install the control rod onto the shift control lever. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the control rod adjusting bolt. Tighten the bolt to 15 Nm (11 lb ft). 5. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 6. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shift Linkage, Transfer Case > Component Information > Service and Repair > Page 8301 1. Install the control rod onto the control lever first. 2. Slide the control rod forward. 3. Install the control rod onto the shift control lever. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the control rod adjusting bolt. Tighten the bolt to 15 Nm (11 lb ft). 5. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 6. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Page 8305 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the speed sensor with a NEW O-ring. Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams Transfer Case Actuator: Diagrams Component Connector End Views Transfer Case Encoder Motor (NQF or NQH) Front Drive Axle Actuator (NQF, NQG or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8309 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Transfer Case Actuator: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8312 Transfer Case Actuator: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8313 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 8320 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 8324 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8329 Shift Solenoid: Specifications 6L45/6L50/6L80/6L90 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 8330 Shift Solenoid: Locations Disassembled Views Control Valve Body Assembly (1 of 2) 350 - Control Valve Body Assembly 353 - Forward Accumulator Oil Seal 354 - Forward Accumulator Piston 355 - Forward Accumulator Pin 356 - Forward Accumulator Spring 357 Forward Abuse Valve 358 - Forward Abuse Valve Spring 359 - Bore Plug 360 - Coiled Spring Pin 360 - Coiled Spring Pin 361 - Low Overrun Valve 362 - Low Overrun Valve Spring 363 - Forward Accumulator Cover 364 - Forward Accumulator Cover Bolt 364a - Pressure Control Solenoid Retainer Bolt 365 - 1-2 Shift Valve Spring - Model Dependent 366 - 1-2 Shift Valve - Model Dependent 367a - 1-2 Shift Solenoid Valve 367b - 2-3 Shift Solenoid Valve 368 - 2-3 Shift Valve 369 - 2-3 Shuttle Valve 370 - 1-2 Accumulator Valve Spring 371 - 1-2 Accumulator Valve 372 - 1-2 Accumulator Valve Sleeve 374 - Actuator Feed Limit Valve 375 - Actuator Feed Limit Valve Spring 376 - Bore Plug 377 - Pressure Control Solenoid Valve Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 8331 378 - Pressure Control Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8334 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8335 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8336 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8337 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8338 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8339 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8340 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8341 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8342 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8343 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8344 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8345 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8346 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8347 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8348 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8349 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8350 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8351 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8352 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8353 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8354 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8355 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8356 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8357 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8358 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8359 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8360 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8361 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8362 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8363 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8364 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8365 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8366 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8367 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8368 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8369 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8370 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8371 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8372 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8373 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8374 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8375 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8376 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8377 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8378 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8379 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8380 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8381 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8382 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8383 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8384 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8385 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8386 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8387 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8388 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8389 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8390 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8391 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8392 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8393 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8394 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8395 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8396 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8397 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8398 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8399 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8400 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8401 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8402 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8403 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8404 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8405 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8406 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8407 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8408 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8409 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8410 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8411 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8412 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8413 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8414 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8415 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8416 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8417 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8418 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8419 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8420 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8421 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8422 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8423 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8424 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8425 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8426 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8427 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8428 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8429 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8430 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8431 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8432 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8433 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8434 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8435 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8436 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8437 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8438 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8439 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8440 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8441 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8442 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8443 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8444 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8445 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8446 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8447 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8448 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8449 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8450 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8451 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8452 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8453 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8454 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8455 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8456 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8457 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8458 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8459 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8460 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8461 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8462 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8463 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8464 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8465 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8466 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8467 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8468 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8469 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8470 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8471 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8472 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8473 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8474 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8475 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8476 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8477 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8478 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8479 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8480 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8481 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8482 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8483 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8484 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8485 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8486 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8487 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8488 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8489 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8490 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8491 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8492 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8493 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8494 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8495 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8496 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8497 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8498 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8499 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8500 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8501 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8502 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8503 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8504 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8505 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8506 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8507 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8508 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8509 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8510 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8511 Shift Solenoid: Connector Views Component Connector End Views Control Solenoid Valve Assembly X1 (MYC, MYD or M99) Control Solenoid Valve Assembly X2 (MYC, MYD or M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8512 Control Solenoid Valve Assembly X3 (MYC, MYD or M99) 1-2 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8513 2-3 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8514 Shift Solenoid (SS) Valve 1 (MW7) Shift Solenoid (SS) Valve 2 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8515 Shift Solenoid (SS) Valve 3 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Note: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). 3. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8518 4. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). 5. Remove the pressure control solenoid (377). Note the orientation upon removal. 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. Installation Procedure Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 1. Install the 1-2 and 2-3 shift solenoids. 2. Install the 1-2 and 2-3 shift solenoid retainers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8519 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 lb in) 4. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 5. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8520 6. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 7. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 8. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM) (See: Automatic Transmission/Transaxle/Description and Operation/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Adaptive Functions (TCM)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8521 Shift Solenoid: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8522 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8527 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8528 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8529 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8530 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8531 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8532 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8533 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8534 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8535 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8536 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8537 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8538 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8539 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8540 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8541 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8542 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8543 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8544 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8545 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8546 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8547 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8548 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8549 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8550 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8551 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8552 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8553 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8554 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8555 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8556 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8557 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8558 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8559 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8560 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8561 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8562 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8563 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8564 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8565 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8566 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8567 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8568 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8569 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8570 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8571 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8572 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8573 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8574 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8575 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8576 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8577 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8578 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8579 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8580 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8581 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8582 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8583 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8584 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8585 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8586 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8587 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8588 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8589 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8590 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8591 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8592 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8593 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8594 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8595 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8596 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8597 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8598 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8599 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8600 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8601 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8602 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8603 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8604 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8605 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8606 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8607 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8608 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8609 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8610 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8611 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8612 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8613 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8614 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8615 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8616 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8617 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8618 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8619 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8620 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8621 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8622 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8623 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8624 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8625 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8626 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8627 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8628 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8629 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8630 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8631 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8632 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8633 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8634 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8635 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8636 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8637 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8638 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8639 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8640 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8641 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8642 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8643 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8644 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8645 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8646 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8647 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8648 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8649 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8650 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8651 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8652 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8653 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8654 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8655 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8656 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8657 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8658 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8659 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8660 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8661 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8662 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8663 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8664 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8665 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8666 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8667 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8668 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8669 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8670 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8671 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8672 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8673 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8674 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8675 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8676 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8677 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8678 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8679 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8680 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8681 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8682 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8683 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8684 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8685 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8686 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8687 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8688 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8689 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8690 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8691 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8692 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8693 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8694 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8695 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8696 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8697 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8698 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8699 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8700 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8701 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8702 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8703 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8704 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8705 Torque Converter Clutch (TCC) Solenoid Valve (M30) Wiring Diagram Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 8706 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and Wiring Harness Special Tools J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission oil pan and the filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 3. Disconnect the transmission harness 20 way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up. Do not pry the connector. Note: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). 5. Disconnect all the internal wiring harness electrical connectors from the electrical components (1-6). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 8707 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the TCC solenoid bolts (68). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 8708 9. Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so the wiring harness hangs down. 10. Remove the solenoid retainer bolt (36A) and the solenoid retainer (378). 11. Remove the pressure control solenoid (377). Note the orientation upon removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 8709 12. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. 13. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the 4 tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 14. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly (66) from the transmission case. 15. Inspect the TCC solenoid and wiring harness assembly for the following defects: * Damage * Cracked connectors * Exposed wires * Loose pins Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 8710 1. Install the wiring harness and TCC solenoid assembly (66) with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. 1. Tighten the control valve body retaining bolts to 11 Nm (97 lb in). 2. Tighten the TCC solenoid retaining bolts to 11 Nm (97 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 8711 Caution: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. 4. Install the following items: 1. The actuator feed limit valve (374) 2. The actuator feed limit valve spring (375) 3. The bore plug (376) 4. The bore plug retainer (395) 5. The pressure control solenoid (377) 6. The solenoid retainer (378) 7. The solenoid retainer bolt (364) Tighten the solenoid retainer bolt to 11 Nm (97 lb in) 5. Install the TCC PWM solenoid to the control valve body. 6. Install the TCC PWM solenoid retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 8712 7. Connect all the internal wiring harness electrical connectors to the electrical components (1-6). 8. Install the 1-2 accumulator. Refer to Accumulator Assembly, Spacer Plate, and Gaskets (See: Automatic Transmission/Transaxle/Accumulator/Service and Repair). 9. Connect the transmission harness 20 way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 10. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 11. Lower the vehicle. 12. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 13. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM) (See: Automatic Transmission/Transaxle/Description and Operation/4L60-E/4L65-E/4L70-E - Automatic Transmission/Transmission Adaptive Functions (TCM)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair Actuator: Service and Repair Front Drive Axle Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Disconnect the electrical connector from the actuator. 4. Remove the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.5 inch axle (4) by turning the actuator counterclockwise. Installation Procedure 1. Apply sealant to the threads of the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.25 inch axle (4). Use the correct sealant. Refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 8717 Adhesives, Fluids, Lubricants, and Sealers (See: Differential Assembly/Fluid Differential/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the actuator (1 or 3). Tighten the actuator to 20 Nm (15 lb ft). 3. Connect the electrical connector to the actuator. 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams Transfer Case Actuator: Diagrams Component Connector End Views Transfer Case Encoder Motor (NQF or NQH) Front Drive Axle Actuator (NQF, NQG or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8722 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Transfer Case Actuator: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8725 Transfer Case Actuator: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8726 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8737 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8738 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8739 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8745 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8746 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8747 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8748 Control Module: Locations Harness Routing Views Engine Chassis Harness Routing - Top Front (Diesel) 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8749 Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8750 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8751 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8752 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8753 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Power Take-Off > Power Take-Off Relay > Component Information > Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF or NQH) Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8762 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8763 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8766 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8780 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8781 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8782 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8788 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8789 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8790 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 8791 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Parking Lock and Manual Shift Detent Lever with Shaft Position Switch Assembly 78 - Steel Cup Plug 79 - Parking Brake Pawl Shaft 80 - Parking Pawl Return Spring 81 - Parking Brake Pawl 82 - Manual Shaft Seal 84 - Manual Shaft - Model Dependent 85 - Parking Lock Actuator Assembly 86 - Parking Lock Bracket 87 - Parking Lock Bracket Bolt 88 - Manual Shift Detent Lever with Shaft Position Switch Assembly 89 - Manual Valve Link 92 - Manual Shift Detent Lever Hub Pin Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8796 Transmission Position Switch/Sensor: Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 8797 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). 2. Remove the following parts: (89), (92), (88), (85) and (84) 3. Remove the manual shaft seal (82) with a screwdriver. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8800 1. Inspect the following items: * Manual shaft (84) for damage or burrs * Parking lock actuator assembly (85) for damage * Manual shift detent lever with shaft position switch assembly (88) for damage or cracks * Manual valve link (89) for damage * Manual shift detent lever pin (92) discard - Do NOT reuse. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the following items: * Manual shift detent lever with shaft position switch assembly (88) * Parking lock actuator assembly (85) * Manual shaft (84) (model dependent) * NEW manual shift detent lever pin (92) * Manual valve link (89) Tighten the nut to 31 Nm (23 lb ft). 3. Install the transmission oil pan and filter. Refer to Automatic Transmission Fluid and Filter Replacement (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8801 Transmission Position Switch/Sensor: Service and Repair 6L45/6L50/6L80/6L90 - Automatic Transmission Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 Nm (9 lb ft). 3. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair). 4. Install the front grill assembly. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4L60-E/4L65-E/4L70-E - Automatic Transmission > Page 8802 Manual Shift Shaft Position Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Speed Sensor: Component Locations 6L45/6L50/6L80/6L90 - Automatic Transmission Disassembled Views Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 - A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 8807 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Oil Pump Assembly 200 - Pump Body 201 - Oil Seal Ring - Slide to Wear Plate 202 - O-Ring Seal - Slide Seal Back-Up 203 - Pump Slide 204 - Pivot Pin Spring 205 - Pivot Slide Pin 208 - Pump Slide Seal Support 209 Pump Slide Seal 210 - Pump Vane Ring 210 - Pump Vane Ring 211 - Rotor Guide 212 - Oil Pump Rotor 213 - Pump Vane 214 - Stator Shaft 215 - Pump Cover 216 - Pressure Regulator Valve Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 8808 217 - Pressure Regulator Valve Spring 218 - Pressure Regulator Isolator Spring 219 - Reverse Boost Valve 220 - Reverse Boost Valve Sleeve 221 - Oil Pump Reverse Boost Valve Retaining Ring 222 - Oil Pump Converter Clutch Valve Retaining Ring 223 - Stop Valve 224 - Converter Clutch Valve - Model Dependent 227 - Pressure Relief Bolt Rivet 228 - Pressure Relief Ball 229 Pressure Relief Spring 230 - Oil Seal Ring - Stator Shaft 231 - Oil Pump Cover Screen Seal 232 Oil Pump Cover Screen 233 - Bolt M8 X 1.25 X 40 - Cover to Body 234 - Stator Shaft Bushing Front 235 - Oil Pump Cover Plug - FWD Clutch Feed 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 236 - Oil Pump Cover Plug 237 - Check Valve Retainer and Ball Assembly 237 - Check Valve Retainer and Ball Assembly 238 - Converter Clutch Signal Orifice - Cup Plug 240 - Cup Orifice Plug 241 Stator Shaft Bushing - Rear 242 - Pump Body Bushing 243 - Oil Seal Assembly 244 - Fluid Seal Retainer 245 - A/T Fluid Pump Slide Outer Spring 246 - Converter Clutch Valve Spring 247 - A/T ISS Attaching Bolt - Model Dependent 249 - O-ring 250 - A/T Input Speed Sensor (ISS) Assembly Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 8809 Transmission Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8810 Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8811 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8812 Transmission Speed Sensor: Service and Repair Input and Output Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 8816 Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection Clutch Pedal Position Sensor Learn Important: The clutch pedal position (CPP) sensor learn procedure is required when the following service procedures have been performed regardless of whether DTC P080A is set: * An engine control module (ECM) replacement * A CPP sensor replacement * Any repairs which affect the CPP sensor relationship 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P080A, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select Clutch Pedal Position Learn under Module Setup in Manual Transmission, and perform the following instructions displayed on the scan tool screen. Important: The CPP sensor learn procedure cannot be performed more than once per ignition cycle. The clutch pedal needs to be fully depressed and held steady throughout this procedure in order to perform a correct learning. 4. The scan tool will display under CPP Learn Status: Not Learned, In Process, Complete, Fail Low Volt, Fail - High Volt, or Fail Moving. The scan tool will display under CPP Learn Status Complete if the process was successful. 5. If the scan tool indicates that DTC P080A ran and passed this ignition the CPP sensor learn procedure is complete. If the scan tool indicates DTC P080A failed or did not run this ignition, refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission). If any other DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC. 6. Turn OFF the ignition for 30 seconds after the learn procedure has successfully completed in order to store the CPP sensor variation values in ECM history. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 8821 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Engine Start Switch Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Remove the plastic retainer (1) tabs from the clutch pedal position switch (2). 3. Remove the clutch pedal position switch (2) from the pushrod. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 8822 1. Install the clutch pedal position switch (2) to the pushrod. 2. Install the plastic retainer (1) tabs to the clutch pedal position switch (2). 3. Connect the clutch pedal position switch electrical connector (1). Warning Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged. 4. Perform the clutch pedal position sensor learn procedure. Refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission) or Clutch Pedal Position Sensor Learn (See: Manual Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Harness Routing Views Engine Harness Routing - Rear (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Dash Panel 2 - Transmission 3 - X175 (M30) 4 - Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8831 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF or NQH) Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8832 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8835 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8836 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8837 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Page 8844 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the speed sensor with a NEW O-ring. Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Service and Repair Braking Sensor/Switch: Service and Repair Brake Master Cylinder Primary Piston Position Sensor Replacement Removal Procedure Note: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Disconnect the brake master cylinder (BMC) primary piston position sensor electrical connector. 4. Remove the 2 BMC primary piston position sensor screws (1). 5. Remove the primary piston position sensor (2). Tilt the rear of the position sensor downward and remove the sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Service and Repair > Page 8850 1. Install the BMC primary piston position sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 2 BMC primary piston position sensor screws (1) and tighten to 10 Nm (89 lb in). 3. Connect the primary piston position sensor electrical connector. 4. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics). 5. If necessary, connect a battery charger to the 12V battery. Refer to Battery Charging (See: Starting and Charging/Battery/Service and Repair/Procedures) 6. Install a scan tool to the vehicle. Note: The ignition switch must remain in the ON position with the engine OFF during this procedure. 7. Turn the ignition ON with the engine OFF. 8. Using the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Module Setup 6. Select BMC Primary Piston Position Relearn and follow the instructions on the scan tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams Electronic Brake Control Module: Diagrams Component Connector End Views Electronic Brake Control Module (EBCM) (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 8854 Electronic Brake Control Module (EBCM) (JF3 or JF7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 8855 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 8856 Electronic Brake Control Module (EBCM) (JH6 or JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 8857 Electronic Brake Control Module (EBCM) (JL4 except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 8858 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 8859 Electronic Brake Control Module (EBCM) (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 8860 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 8861 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Electronic Brake Control Module: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Electronic Brake Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 8864 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 8865 Electronic Brake Control Module: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Electronic Brake Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Hydraulic Control Assembly - Antilock Brakes: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Brake Pressure Modulator Valve Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 8870 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 8871 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Brake Pressure Modulator Valve Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 8872 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Diagrams Lateral Accelerometer: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Diagrams > Page 8876 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Diagrams > Page 8877 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams Wheel Speed Sensor: Diagrams Component Connector End Views Wheel Speed Sensor (WSS) - Left Front (10 Series) Wheel Speed Sensor (WSS) - Left Front (except 10 Series) Wheel Speed Sensor (WSS) - Left Rear (JL4 or HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 8881 Wheel Speed Sensor (WSS) - Right Front (10 Series) Wheel Speed Sensor (WSS) - Right Front (except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 8882 Wheel Speed Sensor (WSS) - Right Rear (JL4 or HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Front Wheel Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 8885 Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Front Wheel Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 8886 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 8887 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 8888 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 8889 Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 8890 2. Disconnect the wheel speed sensor electrical connector (1). 3. Release the wheel speed sensor electrical connector and sensor harness clips (2) from the inboard frame rail. 4. Remove the wheel speed sensor bolt (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 8891 5. Remove the wheel speed sensor (1) from the rear axle. Installation Procedure 1. Install the wheel speed sensor (1) to the rear axle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 8892 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the wheel speed sensor bolt (1) and tighten to 9 Nm (80 lb in). 3. Connect the wheel speed sensor electrical connector (1). 4. Install the wheel speed sensor electrical connector and sensor harness clips (2) to the inboard frame rail. 5. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 8893 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Ring Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Ring Replacement Special Tools * J-8092 - Driver Handle * J-21128 - Axle Pinion Oil Seal Installer * J-23690 - Bearing Installer * J-2619-01 - Slide Hammer * J-45857 - Tone Wheel and/or Bearing Remover * J-45860 - Tone Ring Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). 4. Remove the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 5. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 6. Remove the axle shaft seal, the bearing and the wheel speed sensor ring from the axle housing using the J-2619-01 - Slide Hammer (1) and the J-45857 - Tone Wheel and/or Bearing Remover (2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 8894 1. Install the wheel speed sensor ring using the J-45860 - Tone Ring Installer (1) and the J-8092 Driver Handle (2). 2. Drive the wheel speed sensor ring into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft bearing using the J-23690 - Bearing Installer (1) and the J-8092 - Driver Handle (2). 4. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 8895 5. Install the axle shaft seal using the J-21128 - Axle Pinion Oil Seal Installer. 6. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 7. Install the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 8. Install the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 9. Install the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). 10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 11. Fill the rear axle. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement). 12. Lower the vehicle. Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Ring Replacement Removal Procedure Note: The wheel speed sensor ring is integral to the wheel hub and must be replaced as an assembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 4. Remove the rear axle hub. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). Installation Procedure 1. Install the rear axle hub. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). 2. Install the rear brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 8896 Brake Rotor Replacement (JH7)). 3. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Diagrams Yaw Rate Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Diagrams > Page 8900 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Diagrams > Page 8901 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Yaw Rate Sensor: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 8904 Yaw Rate Sensor: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake Automated Bleed Procedure Less Than 3900 KG (8600 Lb) GVW Antilock Brake System Automated Bleed Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Note: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Using the scan tool, begin the automated bleed procedure. 4. Follow the instructions on the scan tool to complete the automated bleed procedure. Apply the brake pedal when instructed by the scan tool. 5. Turn the ignition OFF. 6. Remove the scan tool from the vehicle. 7. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). 9. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 10. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 11. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 12. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 13. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). 14. Drive the vehicle to exceed 13 km/h (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 15. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Greater Than/Equal to 3900 KG (8600 Lb) GVW Antilock Brake System Automated Bleed Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Note: * Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). * The automated bleed procedure must be performed when a new brake pressure modulator valve (BPMV) is installed, because the secondary circuits of the new BPMV are not prefilled with brake fluid. * The automated bleed procedure is recommended when one of the following conditions exist: * Base brake system bleeding does not achieve the desired pedal height or feel * Extreme loss of brake fluid has occurred * Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out away from the brake modulator assembly, which is then forced out at the brake corners by the pressure bleeder. Automated Bleed Procedure Caution: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 8909 equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Repair or replace components as needed. 4. Lower the vehicle. 5. Prepare the brake bleeding equipment and the vehicle for a pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). 6. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics). 7. Install a scan tool. 8. Turn the ignition ON, with the engine OFF. 9. With the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Special Functions 6. Select Automated Bleed 10. With an assistant ready, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: * Apply the brake pedal when instructed, using moderate effort. * Ensure the pedal remains applied until instructed to release by the scan tool. * Do not exceed the time period allowed by the scan tool for having the bleeder valves open. * The bleed sequence for each corner is as follows: - Left front - Right front - Right rear - Left rear 11. Perform the automated bleed procedure as instructed by the scan tool. 12. If the automated bleed procedure is aborted, a malfunction exists. If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) to diagnose the DTC. 13. After completion of the automated bleed procedure, press and hold the brake pedal to inspect for pedal firmness. 14. If the brake pedal feels spongy, repeat the bleed procedure completely. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 17. Lower the vehicle. 18. Adjust the brake fluid level. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). 19. Road test the vehicle while confirming the brake pedal remains high and firm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 8910 Brake Bleeding: Service and Repair Hydraulic Brake Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 8911 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 8912 Brake Bleeding: Service and Repair Hydraulic Brake Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) Special Tools * J-29532 - Diaphragm Pressure Bleeder, or equivalent * J-35589-A - Brake Pressure Bleeder Adapter Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 6. Check the brake fluid level in the J-29532 - Diaphragm Pressure Bleeder, or equivalent. Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , to the J-35589-A - Brake Pressure Bleeder Adapter. 8. Charge the J-29532 - Diaphragm Pressure Bleeder, or equivalent , air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 8913 install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve, then disconnect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , from the J-35589-A - Brake Pressure Bleeder Adapter. 23. Remove the J-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to the following procedures, as appropriate: * Antilock Brake System Automated Bleed (See: )for Two-mode Hybrid vehicles * Antilock Brake System Automated Bleed (See: )for non-hybrid vehicles less than 3900 kg (8600 lb) GVW * Antilock Brake System Automated Bleed (See: )for non-hybrid vehicles greater than/equal to 3900 kg (8600 lb) GVW 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 8914 Brake Bleeding: Service and Repair Hydraulic Brake Flushing Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance - oil-based substance - Layered appearance - silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (Vacuum Assist) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Hydraulic Assist) ( See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) * Front Brake Hose Replacement (JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JH6, JH7))Front Brake Hose Replacement (JD9, JF3, JF7, JG4) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JD9, JF3, JF7, JG4)) * Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4))Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4))Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JH6, JH7))Rear Brake Hose Replacement (To Caliper - JD9) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Caliper - JD9))Rear Brake Hose Replacement (Caliper - JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper - JH6, JH7)) * Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) * Rear Brake Caliper Replacement (JD9) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Less than 3900 kg (8600 lb) GVW) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 8915 Refer to the procedures indicated: * Master Cylinder Replacement (Vacuum Assist) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Hydraulic Assist) ( See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) ; also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (Vacuum Assist) (See: Hydraulic System/Brake Fluid Reservoir/Service and Repair/Master Cylinder Reservoir Replacement (Vacuum Assist))Master Cylinder Reservoir Replacement (Hydraulic Assist) (See: Hydraulic System/Brake Fluid Reservoir/Service and Repair/Master Cylinder Reservoir Replacement (Hydraulic Assist))Master Cylinder Reservoir Replacement (Two-mode Hybrid) (). Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JH6, JH7))Front Brake Hose Replacement (JD9, JF3, JF7, JG4) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JD9, JF3, JF7, JG4)) * Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4))Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4))Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JH6, JH7))Rear Brake Hose Replacement (To Caliper - JD9) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Caliper - JD9))Rear Brake Hose Replacement (Caliper - JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper - JH6, JH7)) * Front Brake Caliper Overhaul (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Overhaul/Front Brake Caliper Overhaul (JH6, JH7)) or Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) ( See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) * Rear Brake Caliper Overhaul (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Overhaul/Rear Brake Caliper Overhaul (JH6, JH7)) or Rear Brake Caliper Replacement (JD9) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Less than 3900 kg (8600 lb) GVW) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canada P/N 992667) or equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair Brake Pedal Assy: Service and Repair Brake Pedal Assembly Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Page 8919 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Testing and Inspection Brake Caliper: Testing and Inspection Brake Caliper Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement. 4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. * For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. * For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement Brake Caliper: Removal and Replacement Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8926 Front Brake Caliper Replacement (JH6, JH7) Front Brake Caliper Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8927 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8928 Rear Brake Caliper Replacement (JD9) Rear Brake Caliper Replacement (JD9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8929 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8930 Rear Brake Caliper Replacement (JH6, JH7) Rear Brake Caliper Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8931 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8932 Front Brake Caliper Hardware Replacement (JD9, JF3, JF7, JG4) Front Brake Caliper Hardware Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8933 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8934 Front Brake Caliper Hardware Replacement (JH6, JH7) Front Brake Caliper Hardware Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8935 Rear Brake Caliper Hardware Replacement (JD9) Rear Brake Caliper Hardware Replacement (JD9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8936 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8937 Rear Brake Caliper Hardware Replacement (JH6, JH7) Rear Brake Caliper Hardware Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8938 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8939 Front Brake Caliper Bracket Replacement (JD9, JF3, JF7, JG4) Front Brake Caliper Bracket Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8940 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8941 Front Brake Caliper Bracket Replacement (JH6, JH7) Front Brake Caliper Bracket Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8942 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8943 Rear Brake Caliper Bracket Replacement (JD9) Rear Brake Caliper Bracket Replacement (JD9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8944 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8945 Rear Brake Caliper Bracket Replacement (JH6, JH7) Rear Brake Caliper Bracket Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8946 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8947 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8948 Brake Caliper: Overhaul Front Brake Caliper Overhaul (JH6, JH7) Front Brake Caliper Overhaul (JH6, JH7) Disassembly Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Remove the brake caliper. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)). 2. Drain all the brake fluid from the caliper. Note: The brake calipers use phenolic pistons that have stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8949 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8950 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered , non-lubricated compressed air. Assembly Procedure Note: When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure that the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure that the square-cut piston seal is not twisted. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8951 4. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. Note: Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8952 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 Nm (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)). Rear Brake Caliper Overhaul (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8953 Rear Brake Caliper Overhaul (JH6, JH7) Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Disassembly Procedure 1. Remove the brake caliper. Refer to Rear Brake Caliper Replacement (JD9) (See: Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)). 2. Drain all the brake fluid from the caliper. Note: The brake calipers use phenolic pistons with stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8954 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8955 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered , non-lubricated compressed air. Assembly Procedure Note: When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure the square-cut piston seal is not twisted. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8956 4. Install the boot over the end of the piston so the fold will face toward the brake caliper housing piston bore opening. Note: Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 8957 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 Nm (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Refer to Rear Brake Caliper Replacement (JD9) (See: Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest: > 10-05-23-001B > Apr > 11 > Brakes - Front Brake Induced Pulsation/Vibration Brake Pad: Customer Interest Brakes - Front Brake Induced Pulsation/Vibration TECHNICAL Bulletin No.: 10-05-23-001B Date: April 13, 2011 Subject: Brake Induced Pulsation/Vibration Felt in Steering Wheel, Rumble Noise from Underbody During Downhill Descent (Verify Condition and Replace Front Brake Pads) Models: 2008 Chevrolet Silverado Light Duty (LD) 2008 GMC Sierra Light Duty (LD) 2nd-Design Only - w/ Pad Spreading Spring Clips (Refer to PIT4611 for Design Identification) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) 2009-2012 Chevrolet Silverado Light Duty (LD) 2009-2012 GMC Sierra Light Duty (LD) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) or (RPO JF7) and Stabilitrak (RPO JL4) Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 10-05-23-00A (Section 05 - Brakes). Condition Some customers may comment on a pulsation or vibration mostly concentrated in the steering wheel during downhill descent as specifically described. This condition will most often begin as an increasing rumbling noise coming from the underbody or the front of the vehicle. This condition is exhibited mostly in mountainous regions. Note Use care to ensure the following diagnosis and repair are only attempted if the conditions and concern match those listed, and if the concern can be duplicated under the same conditions. This condition occurs ONLY under the following conditions: - When the vehicle is driven as follows: - On a downhill descent on a fairly steep grade (approximately 5% or greater). - On taller hills (roughly 1.5‹›km [1‹›mi] road length or greater), without sharp turns. - At speeds above 64‹›km/h (40‹›mph). - Using the brakes just enough to maintain the speed limit when moving downhill. - Typically, a rumbling noise will be heard first, building in intensity, followed by increasing pulsation, or vibration, felt in the steering wheel, then typically felt in the floor panel. - The condition will be eliminated once the vehicle is driven on relatively flat ground, typically for 1.5-3‹›km (1-2 mi). Cause This condition may be caused by interaction between the front brake lining material and the front brake rotors. Correction Important DO NOT attempt any repairs on the vehicle until you verify the specific condition is present by following the steps below: 1. Warm up the vehicle by driving approximately 8 km (5 mi). 2. Drive the vehicle in the lane closest to the side of the fairly steep grade (roughly 5 percent or greater), taller hill (roughly 1.5 km [1‹›mi] road length or greater), without sharp turns, and with a speed limit of 64 km/h (40 mph) or greater, with the side windows down. 3. While in Drive, descending downhill, apply the brakes naturally, only as needed, to maintain the speed limit. 4. Observe for noise, followed by pulsation/vibration. Observe where the noise, pulsation and/or vibration are most noticeable. 5. Drive the vehicle on relatively flat ground for 1.5-3 km (1-2 mi) to verify that the condition goes away completely. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest: > 10-05-23-001B > Apr > 11 > Brakes - Front Brake Induced Pulsation/Vibration > Page 8966 If the Front Pad Kit listed is used to correct any condition other than the condition described in this bulletin, the vehicle could experience higher mileage corrosion-induced brake pulsation. If the condition described HAS NOT been verified, or if the condition observed IS NOT most noticeable through the steering wheel, the observed condition may have a different cause, such as a tire/wheel or rear brake issue, etc. Refer to SI for any further related diagnostics. If the condition described has been verified, and if the condition is most noticeable through the steering wheel, and if the condition was eliminated after driving the vehicle on relatively flat ground, typically for 1.5-3‹›km (1-2 mi), perform the following inspections and repairs. Important - It is critical to use the proper OEM brake rotors. Use of Non-OEM rotors may prevent the condition from being corrected long term. - If Non-OEM rotors are identified, these rotors are NOT covered under the GM New Vehicle Limited Warranty. 1. Inspect the front brake rotors to ensure that they are OEM rotors. - Remove the brake rotor from the vehicle. - Inspect the back side of the rotor for the Bosch Logo. If the Bosch logo IS NOT present, replace with OEM GM rotors, P/N 25819670. 2. Inspect the front brake rotors for Assembled Lateral Runout (LRO) and thickness variation. Follow SI procedures. 3. Inspect the front brake rotors for minimum thickness. Follow SI procedures. 4. If the rotors are within specifications, DO NOT refinish or replace the rotors. 5. If the rotors are out of specifications, refinish the rotors on a qualified lathe, or replace the rotors as appropriate. Follow SI procedures. Note To prevent a noise concern, follow the brake pad insulator preparation and seating instructions as referenced in Front Brake Pad Replacement (1500) in SI. 6. Install the specified front pad kit, GM P/N 25910432. Follow SI procedures. 7. Ensure that the condition has been eliminated under the same conditions. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest: > 10-05-23-001B > Apr > 11 > Brakes - Front Brake Induced Pulsation/Vibration > Page 8967 For vehicles repaired under warranty, use the table. Note H9745 includes time for road testing and for removal of 1 rotor to inspect for OEM markings. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-05-23-001B > Apr > 11 > Brakes - Front Brake Induced Pulsation/Vibration Brake Pad: All Technical Service Bulletins Brakes - Front Brake Induced Pulsation/Vibration TECHNICAL Bulletin No.: 10-05-23-001B Date: April 13, 2011 Subject: Brake Induced Pulsation/Vibration Felt in Steering Wheel, Rumble Noise from Underbody During Downhill Descent (Verify Condition and Replace Front Brake Pads) Models: 2008 Chevrolet Silverado Light Duty (LD) 2008 GMC Sierra Light Duty (LD) 2nd-Design Only - w/ Pad Spreading Spring Clips (Refer to PIT4611 for Design Identification) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) 2009-2012 Chevrolet Silverado Light Duty (LD) 2009-2012 GMC Sierra Light Duty (LD) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) or (RPO JF7) and Stabilitrak (RPO JL4) Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 10-05-23-00A (Section 05 - Brakes). Condition Some customers may comment on a pulsation or vibration mostly concentrated in the steering wheel during downhill descent as specifically described. This condition will most often begin as an increasing rumbling noise coming from the underbody or the front of the vehicle. This condition is exhibited mostly in mountainous regions. Note Use care to ensure the following diagnosis and repair are only attempted if the conditions and concern match those listed, and if the concern can be duplicated under the same conditions. This condition occurs ONLY under the following conditions: - When the vehicle is driven as follows: - On a downhill descent on a fairly steep grade (approximately 5% or greater). - On taller hills (roughly 1.5‹›km [1‹›mi] road length or greater), without sharp turns. - At speeds above 64‹›km/h (40‹›mph). - Using the brakes just enough to maintain the speed limit when moving downhill. - Typically, a rumbling noise will be heard first, building in intensity, followed by increasing pulsation, or vibration, felt in the steering wheel, then typically felt in the floor panel. - The condition will be eliminated once the vehicle is driven on relatively flat ground, typically for 1.5-3‹›km (1-2 mi). Cause This condition may be caused by interaction between the front brake lining material and the front brake rotors. Correction Important DO NOT attempt any repairs on the vehicle until you verify the specific condition is present by following the steps below: 1. Warm up the vehicle by driving approximately 8 km (5 mi). 2. Drive the vehicle in the lane closest to the side of the fairly steep grade (roughly 5 percent or greater), taller hill (roughly 1.5 km [1‹›mi] road length or greater), without sharp turns, and with a speed limit of 64 km/h (40 mph) or greater, with the side windows down. 3. While in Drive, descending downhill, apply the brakes naturally, only as needed, to maintain the speed limit. 4. Observe for noise, followed by pulsation/vibration. Observe where the noise, pulsation and/or vibration are most noticeable. 5. Drive the vehicle on relatively flat ground for 1.5-3 km (1-2 mi) to verify that the condition goes away completely. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-05-23-001B > Apr > 11 > Brakes - Front Brake Induced Pulsation/Vibration > Page 8973 If the Front Pad Kit listed is used to correct any condition other than the condition described in this bulletin, the vehicle could experience higher mileage corrosion-induced brake pulsation. If the condition described HAS NOT been verified, or if the condition observed IS NOT most noticeable through the steering wheel, the observed condition may have a different cause, such as a tire/wheel or rear brake issue, etc. Refer to SI for any further related diagnostics. If the condition described has been verified, and if the condition is most noticeable through the steering wheel, and if the condition was eliminated after driving the vehicle on relatively flat ground, typically for 1.5-3‹›km (1-2 mi), perform the following inspections and repairs. Important - It is critical to use the proper OEM brake rotors. Use of Non-OEM rotors may prevent the condition from being corrected long term. - If Non-OEM rotors are identified, these rotors are NOT covered under the GM New Vehicle Limited Warranty. 1. Inspect the front brake rotors to ensure that they are OEM rotors. - Remove the brake rotor from the vehicle. - Inspect the back side of the rotor for the Bosch Logo. If the Bosch logo IS NOT present, replace with OEM GM rotors, P/N 25819670. 2. Inspect the front brake rotors for Assembled Lateral Runout (LRO) and thickness variation. Follow SI procedures. 3. Inspect the front brake rotors for minimum thickness. Follow SI procedures. 4. If the rotors are within specifications, DO NOT refinish or replace the rotors. 5. If the rotors are out of specifications, refinish the rotors on a qualified lathe, or replace the rotors as appropriate. Follow SI procedures. Note To prevent a noise concern, follow the brake pad insulator preparation and seating instructions as referenced in Front Brake Pad Replacement (1500) in SI. 6. Install the specified front pad kit, GM P/N 25910432. Follow SI procedures. 7. Ensure that the condition has been eliminated under the same conditions. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-05-23-001B > Apr > 11 > Brakes - Front Brake Induced Pulsation/Vibration > Page 8974 For vehicles repaired under warranty, use the table. Note H9745 includes time for road testing and for removal of 1 rotor to inspect for OEM markings. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8980 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8981 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8982 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8988 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8989 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8990 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 8991 Brake Pad: Specifications Replace the disc brake pads when the friction surface (3) is worn to within 0.76 mm (0.030 in) of the mounting plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 8992 Brake Pad: Testing and Inspection Brake Pad Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are removed from the vehicle. 2. If replacement is necessary, always replace disc brake pads in axle sets. 3. Inspect both edges of the disc brake pad friction surfaces (3). The highest rate of wear normally occurs at the trailing edge of the disc brake pads. 4. Inspect the thickness of the disc brake pads (3) in order to ensure that they have not worn prematurely. The disc brake pad wear should be approximately even per axle set. 5. Both front and rear disc brake pads have integral, audible wear sensors (1). When the disc brake pad wear reaches the minimum allowable thickness, the wear sensor contacts the disc brake rotor (2). The wear indicator will then produce an audible, high-pitched warning noise during wheel rotation. 6. Replace the disc brake pads when the friction surface (3) is worn to within 0.76 mm (0.030 in) of the mounting plates. 7. Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake pads to ensure that they are level. Place the disc brake pad friction surfaces together and measure the gap between the surfaces. If more than 0.13 mm (0.005 in) gap exists midway between the length of the disc brake pads, replace the disc brake pads. 8. Verify that any disc brake pad shims that may be required are in place and not damaged or excessively corroded. Replace any missing or damaged shims in order to preserve proper disc brake performance. 9. Replace the disc brake pads if any have separated from the mounting plates. 10. Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause noise or otherwise impair disc brake performance. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures Brake Pad: Procedures Brake Pad and Rotor Burnishing Warning Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Note: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 8995 Brake Pad: Removal and Replacement Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4) Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 8996 Front Disc Brake Pads Replacement (JH6, JH7) Front Disc Brake Pads Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 8997 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 8998 Rear Disc Brake Pads Replacement (JD9) Rear Disc Brake Pads Replacement (JD9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 8999 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 9000 Rear Disc Brake Pads Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 9001 Rear Disc Brake Pads Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 9002 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest: > 10-05-23-001B > Apr > 11 > Brakes - Front Brake Induced Pulsation/Vibration Brake Rotor/Disc: Customer Interest Brakes - Front Brake Induced Pulsation/Vibration TECHNICAL Bulletin No.: 10-05-23-001B Date: April 13, 2011 Subject: Brake Induced Pulsation/Vibration Felt in Steering Wheel, Rumble Noise from Underbody During Downhill Descent (Verify Condition and Replace Front Brake Pads) Models: 2008 Chevrolet Silverado Light Duty (LD) 2008 GMC Sierra Light Duty (LD) 2nd-Design Only - w/ Pad Spreading Spring Clips (Refer to PIT4611 for Design Identification) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) 2009-2012 Chevrolet Silverado Light Duty (LD) 2009-2012 GMC Sierra Light Duty (LD) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) or (RPO JF7) and Stabilitrak (RPO JL4) Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 10-05-23-00A (Section 05 - Brakes). Condition Some customers may comment on a pulsation or vibration mostly concentrated in the steering wheel during downhill descent as specifically described. This condition will most often begin as an increasing rumbling noise coming from the underbody or the front of the vehicle. This condition is exhibited mostly in mountainous regions. Note Use care to ensure the following diagnosis and repair are only attempted if the conditions and concern match those listed, and if the concern can be duplicated under the same conditions. This condition occurs ONLY under the following conditions: - When the vehicle is driven as follows: - On a downhill descent on a fairly steep grade (approximately 5% or greater). - On taller hills (roughly 1.5‹›km [1‹›mi] road length or greater), without sharp turns. - At speeds above 64‹›km/h (40‹›mph). - Using the brakes just enough to maintain the speed limit when moving downhill. - Typically, a rumbling noise will be heard first, building in intensity, followed by increasing pulsation, or vibration, felt in the steering wheel, then typically felt in the floor panel. - The condition will be eliminated once the vehicle is driven on relatively flat ground, typically for 1.5-3‹›km (1-2 mi). Cause This condition may be caused by interaction between the front brake lining material and the front brake rotors. Correction Important DO NOT attempt any repairs on the vehicle until you verify the specific condition is present by following the steps below: 1. Warm up the vehicle by driving approximately 8 km (5 mi). 2. Drive the vehicle in the lane closest to the side of the fairly steep grade (roughly 5 percent or greater), taller hill (roughly 1.5 km [1‹›mi] road length or greater), without sharp turns, and with a speed limit of 64 km/h (40 mph) or greater, with the side windows down. 3. While in Drive, descending downhill, apply the brakes naturally, only as needed, to maintain the speed limit. 4. Observe for noise, followed by pulsation/vibration. Observe where the noise, pulsation and/or vibration are most noticeable. 5. Drive the vehicle on relatively flat ground for 1.5-3 km (1-2 mi) to verify that the condition goes away completely. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest: > 10-05-23-001B > Apr > 11 > Brakes - Front Brake Induced Pulsation/Vibration > Page 9011 If the Front Pad Kit listed is used to correct any condition other than the condition described in this bulletin, the vehicle could experience higher mileage corrosion-induced brake pulsation. If the condition described HAS NOT been verified, or if the condition observed IS NOT most noticeable through the steering wheel, the observed condition may have a different cause, such as a tire/wheel or rear brake issue, etc. Refer to SI for any further related diagnostics. If the condition described has been verified, and if the condition is most noticeable through the steering wheel, and if the condition was eliminated after driving the vehicle on relatively flat ground, typically for 1.5-3‹›km (1-2 mi), perform the following inspections and repairs. Important - It is critical to use the proper OEM brake rotors. Use of Non-OEM rotors may prevent the condition from being corrected long term. - If Non-OEM rotors are identified, these rotors are NOT covered under the GM New Vehicle Limited Warranty. 1. Inspect the front brake rotors to ensure that they are OEM rotors. - Remove the brake rotor from the vehicle. - Inspect the back side of the rotor for the Bosch Logo. If the Bosch logo IS NOT present, replace with OEM GM rotors, P/N 25819670. 2. Inspect the front brake rotors for Assembled Lateral Runout (LRO) and thickness variation. Follow SI procedures. 3. Inspect the front brake rotors for minimum thickness. Follow SI procedures. 4. If the rotors are within specifications, DO NOT refinish or replace the rotors. 5. If the rotors are out of specifications, refinish the rotors on a qualified lathe, or replace the rotors as appropriate. Follow SI procedures. Note To prevent a noise concern, follow the brake pad insulator preparation and seating instructions as referenced in Front Brake Pad Replacement (1500) in SI. 6. Install the specified front pad kit, GM P/N 25910432. Follow SI procedures. 7. Ensure that the condition has been eliminated under the same conditions. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest: > 10-05-23-001B > Apr > 11 > Brakes - Front Brake Induced Pulsation/Vibration > Page 9012 For vehicles repaired under warranty, use the table. Note H9745 includes time for road testing and for removal of 1 rotor to inspect for OEM markings. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 10-05-23-001B > Apr > 11 > Brakes - Front Brake Induced Pulsation/Vibration Brake Rotor/Disc: All Technical Service Bulletins Brakes - Front Brake Induced Pulsation/Vibration TECHNICAL Bulletin No.: 10-05-23-001B Date: April 13, 2011 Subject: Brake Induced Pulsation/Vibration Felt in Steering Wheel, Rumble Noise from Underbody During Downhill Descent (Verify Condition and Replace Front Brake Pads) Models: 2008 Chevrolet Silverado Light Duty (LD) 2008 GMC Sierra Light Duty (LD) 2nd-Design Only - w/ Pad Spreading Spring Clips (Refer to PIT4611 for Design Identification) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) 2009-2012 Chevrolet Silverado Light Duty (LD) 2009-2012 GMC Sierra Light Duty (LD) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) or (RPO JF7) and Stabilitrak (RPO JL4) Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 10-05-23-00A (Section 05 - Brakes). Condition Some customers may comment on a pulsation or vibration mostly concentrated in the steering wheel during downhill descent as specifically described. This condition will most often begin as an increasing rumbling noise coming from the underbody or the front of the vehicle. This condition is exhibited mostly in mountainous regions. Note Use care to ensure the following diagnosis and repair are only attempted if the conditions and concern match those listed, and if the concern can be duplicated under the same conditions. This condition occurs ONLY under the following conditions: - When the vehicle is driven as follows: - On a downhill descent on a fairly steep grade (approximately 5% or greater). - On taller hills (roughly 1.5‹›km [1‹›mi] road length or greater), without sharp turns. - At speeds above 64‹›km/h (40‹›mph). - Using the brakes just enough to maintain the speed limit when moving downhill. - Typically, a rumbling noise will be heard first, building in intensity, followed by increasing pulsation, or vibration, felt in the steering wheel, then typically felt in the floor panel. - The condition will be eliminated once the vehicle is driven on relatively flat ground, typically for 1.5-3‹›km (1-2 mi). Cause This condition may be caused by interaction between the front brake lining material and the front brake rotors. Correction Important DO NOT attempt any repairs on the vehicle until you verify the specific condition is present by following the steps below: 1. Warm up the vehicle by driving approximately 8 km (5 mi). 2. Drive the vehicle in the lane closest to the side of the fairly steep grade (roughly 5 percent or greater), taller hill (roughly 1.5 km [1‹›mi] road length or greater), without sharp turns, and with a speed limit of 64 km/h (40 mph) or greater, with the side windows down. 3. While in Drive, descending downhill, apply the brakes naturally, only as needed, to maintain the speed limit. 4. Observe for noise, followed by pulsation/vibration. Observe where the noise, pulsation and/or vibration are most noticeable. 5. Drive the vehicle on relatively flat ground for 1.5-3 km (1-2 mi) to verify that the condition goes away completely. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 10-05-23-001B > Apr > 11 > Brakes - Front Brake Induced Pulsation/Vibration > Page 9018 If the Front Pad Kit listed is used to correct any condition other than the condition described in this bulletin, the vehicle could experience higher mileage corrosion-induced brake pulsation. If the condition described HAS NOT been verified, or if the condition observed IS NOT most noticeable through the steering wheel, the observed condition may have a different cause, such as a tire/wheel or rear brake issue, etc. Refer to SI for any further related diagnostics. If the condition described has been verified, and if the condition is most noticeable through the steering wheel, and if the condition was eliminated after driving the vehicle on relatively flat ground, typically for 1.5-3‹›km (1-2 mi), perform the following inspections and repairs. Important - It is critical to use the proper OEM brake rotors. Use of Non-OEM rotors may prevent the condition from being corrected long term. - If Non-OEM rotors are identified, these rotors are NOT covered under the GM New Vehicle Limited Warranty. 1. Inspect the front brake rotors to ensure that they are OEM rotors. - Remove the brake rotor from the vehicle. - Inspect the back side of the rotor for the Bosch Logo. If the Bosch logo IS NOT present, replace with OEM GM rotors, P/N 25819670. 2. Inspect the front brake rotors for Assembled Lateral Runout (LRO) and thickness variation. Follow SI procedures. 3. Inspect the front brake rotors for minimum thickness. Follow SI procedures. 4. If the rotors are within specifications, DO NOT refinish or replace the rotors. 5. If the rotors are out of specifications, refinish the rotors on a qualified lathe, or replace the rotors as appropriate. Follow SI procedures. Note To prevent a noise concern, follow the brake pad insulator preparation and seating instructions as referenced in Front Brake Pad Replacement (1500) in SI. 6. Install the specified front pad kit, GM P/N 25910432. Follow SI procedures. 7. Ensure that the condition has been eliminated under the same conditions. Parts Information Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 10-05-23-001B > Apr > 11 > Brakes - Front Brake Induced Pulsation/Vibration > Page 9019 For vehicles repaired under warranty, use the table. Note H9745 includes time for road testing and for removal of 1 rotor to inspect for OEM markings. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9024 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9025 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9026 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9027 WARRANTY INFORMATION Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9028 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9029 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9030 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9031 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9032 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9033 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9034 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9035 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9036 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9037 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9043 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9044 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9045 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9046 WARRANTY INFORMATION Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9047 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9048 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9049 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9050 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9051 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9052 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9053 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9054 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9055 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 00-05-22-002L > Mar > 09 > Brakes- Disc Brake Warranty Service And Procedures > Page 9056 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 9057 Brake Rotor/Disc: Specifications Front Brakes JD9, JF3, JF7 Rotor Discard Thickness*........................................................................ ....................................................................................................28.0 mm (1.10 in) Rotor Minimum Allowable Thickness After Refinish..................................................................................................................................28.0 mm (1.10 in) Rotor Thickness (new)........................................................................................................... ....................................................................30.0 mm (1.181 in) Rotor Maximum Allowable Assembled Lateral Runout.............................................................................................................................0.05 mm (0.002 in) Rotor Maximum Allowable Scoring...................................................................................... .....................................................................1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation.....................................................................................................................................0.025 mm (0.001 in) Front Brakes JH6, JH7 Rotor Discard Thickness*........................................................ ................................................................................................................36.50 mm (1.437 in) Rotor Minimum Allowable Thickness After Refinish................................................................................................................................37.0 mm (1.457 in) Rotor Thickness (new)......................................................................................................... ......................................................................38.0 mm (1.496 in) Rotor Maximum Allowable Assembled Lateral Runout.............................................................................................................................0.13 mm (0.005 in) Rotor Maximum Allowable Scoring...................................................................................... .....................................................................1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation.....................................................................................................................................0.025 mm (0.001 in) Rear Brakes JD9 Rotor Discard Thickness*................................................................. .........................................................................................................18.0 mm (0.709 in) Rotor Minimum Allowable Thickness After Refinish..............................................................................................................................18.5 mm (0.7282 in) Rotor Thickness (new)....................................................................................................... ........................................................................20.0 mm (0.787 in) Rotor Maximum Allowable Assembled Lateral Runout.............................................................................................................................0.05 mm (0.002 in) Rotor Maximum Allowable Scoring...................................................................................... .....................................................................1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation...................................................................................................................................0.009 mm (0.0004 in) Rear Brakes JH6 Rotor Discard Thickness*............................................................... ...........................................................................................................27.5 mm (1.083 in) Rotor Minimum Allowable Thickness After Refinish................................................................................................................................28.0 mm (1.102 in) Rotor Thickness (new)......................................................................................................... ......................................................................30.0 mm (1.181 in) Rotor Maximum Allowable Assembled Lateral Runout.............................................................................................................................0.13 mm (0.005 in) Rotor Maximum Allowable Scoring...................................................................................... .....................................................................1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation.....................................................................................................................................0.025 mm (0.001 in) Rear Brakes JH7 Rotor Discard Thickness*................................................................. .........................................................................................................28.5 mm (1.122 in) Rotor Minimum Allowable Thickness After Refinish................................................................................................................................29.0 mm (1.142 in) Rotor Thickness (new)......................................................................................................... ......................................................................30.0 mm (1.181 in) Rotor Maximum Allowable Assembled Lateral Runout.............................................................................................................................0.13 mm (0.005 in) Rotor Maximum Allowable Scoring...................................................................................... .....................................................................1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation.....................................................................................................................................0.025 mm (0.001 in) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing Brake Rotor/Disc: Testing and Inspection Brake Pad and Rotor Burnishing Brake Pad and Rotor Burnishing Warning Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Note: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9060 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Brake Rotor Assembled Lateral Runout Correction Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired. * The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots between related components. Refer to Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled Lateral Runout Correction - Indexing). * The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe (See: Brake Rotor Assembled Lateral Runout Correction On Vehicle Lathe). If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9061 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Indexing Brake Rotor Assembled Lateral Runout Correction - Indexing Special Tools * CH-39544-KIT - Complete Torque Socket Set - 10 PCS , or equivalent * CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11, 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Remove the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the CH-45101-100 - Conical Brake Rotor Washers (1) and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9062 6. Install the remaining CH-45101-100 - Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the CH-39544-KIT - Complete Torque Socket Set - 10 PCS , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 9. Compare the amount of change between this measurement and the original measurement. 10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained. 12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9063 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Special Tools CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor. 2. Remove the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). 7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10. 8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 9. Remove the lathe from the vehicle. 10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9064 Brake Rotor/Disc: Testing and Inspection Brake Pad and Rotor Burnishing Brake Pad and Rotor Burnishing Warning Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Note: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Brake Rotor Assembled Lateral Runout Correction Brake Rotor Assembled Lateral Runout Correction Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired. * The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots between related components. Refer to Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled Lateral Runout Correction - Indexing). * The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe (See: Brake Rotor Assembled Lateral Runout Correction On Vehicle Lathe). If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern. Brake Rotor Assembled Lateral Runout Correction - Indexing Brake Rotor Assembled Lateral Runout Correction - Indexing Special Tools * CH-39544-KIT - Complete Torque Socket Set - 10 PCS , or equivalent * CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9065 Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11, 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Remove the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the CH-45101-100 - Conical Brake Rotor Washers (1) and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9066 6. Install the remaining CH-45101-100 - Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the CH-39544-KIT - Complete Torque Socket Set - 10 PCS , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 9. Compare the amount of change between this measurement and the original measurement. 10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained. 12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts. Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Special Tools CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor. 2. Remove the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9067 4. Set up the lathe, following the manufacturer's instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). 7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10. 8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 9. Remove the lathe from the vehicle. 10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts. Brake Rotor Assembled Lateral Runout Measurement Brake Rotor Assembled Lateral Runout Measurement Special Tools * J-39544-KIT - Torque-Limiting Socket Set , or equivalent * J-41013 - Rotor Resurfacing Kit * J-42450-A - Wheel Hub Resurfacing Kit * J-45101 - Hub and Wheel Runout Gauge * J-45101-100 - Conical Brake Rotor Washers Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). 1. Matchmark the position of the brake rotor to the wheel studs if this has not been done already. Note: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles, corrosion, rust, or debris remaining. If the wheel hub/axle flange and/or if the brake rotor mating surfaces exhibit these conditions, perform the following steps: 1. Remove the brake rotor from the vehicle. Refer to Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) (See: Service and Repair/Front Brake Rotor Replacement (JD9, JF3, JF7, JG4))Front Brake Rotor Replacement (JH6, JH7) (See: Service and Repair/Front Brake Rotor Replacement (JH6, JH7)) and/or Rear Brake Rotor Replacement (JD9) (See: Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Service and Repair/Rear Brake Rotor Replacement (JH7)). 2. Using the J-42450-A - Wheel Hub Resurfacing Kit , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 3. Using the J-41013 - Rotor Resurfacing Kit , thoroughly clean any rust or corrosion from the mating surface of the brake rotor. 4. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Install the rotor to the hub/axle flange using the matchmark made prior to removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9068 4. Hold the rotor firmly in place against the hub/axle flange and install one of the J-45101-100 Conical Brake Rotor Washers (1), and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 6. Install the remaining J-45101-100 - Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the J-39544-KIT - Torque-Limiting Socket Set , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. If the brake rotor has been REFINISHED or REPLACED with a new rotor, proceed to step 14. 9. If the brake rotor meets the following criteria, proceed to step 10. * The rotor is within specifications and is being REUSED * The rotor has NOT been refinished * The rotor does NOT exhibit thickness variation exceeding the maximum allowable level Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9069 10. Mount a dial indicator, J-45101 - Hub and Wheel Runout Gauge , or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. 11. Measure and record the assembled LRO of the brake rotor. 1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO. 12. Compare the brake rotor assembled LRO to the following specifications: Brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) Brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) Brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) 13. If the brake rotor assembled LRO is within specifications, proceed to step 18. If the brake rotor assembled LRO exceeds the specification, refinish the rotor to ensure true parallelism, refer to Brake Rotor Refinishing (See: Brake Rotor Refinishing). After refinishing the rotor, proceed to step 14. 14. Mount a dial indicator, J-45101 - Hub and Wheel Runout Gauge , or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. 15. Measure and record the assembled LRO of the brake rotor. 1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO. 16. Compare the brake rotor assembled LRO to the following specification: Brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) Brake rotor maximum allowable assembled lateral runout: 0.13 mm (0.005 in) 17. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 18. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J-45101-100 - Conical Brake Rotor Washers and the lug nuts. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9070 Brake Rotor Refinishing Brake Rotor Refinishing Special Tools * CH-41013 - Rotor Resurfacing Kit * CH-42450-A - Wheel Hub Resurfacing Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * The disc brake rotors do not require refinishing as part of routine brake system service. New disc brake rotors do not require refinishing. Do not refinish disc brake rotors in an attempt to correct the following conditions: - Brake system noise - squeal, growl, groan - Uneven and/or premature disc brake pad wear - Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface - Scoring of the disc brake rotor friction surface less than the maximum allowable specification * Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow the rotor to be refinished and remain above the minimum allowable thickness after refinish specification. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if one or more of the following conditions exist: - Thickness variation in excess of the maximum allowable specification - Excessive corrosion/rust and/or pitting - Cracks and/or heat spots - Excessive blueing discoloration - Scoring of the disc brake rotor surface in excess of the maximum allowable specification * Disc brake rotors may need to be refinished as part of the process for correcting brake rotor assembled lateral runout (LRO) that exceeds the maximum allowable specification. Note: If the vehicle is equipped with cross-drilled rotors, use a lathe with positive rake tooling. This setup requires less cutting pressure, which will result in less vibration, and a better surface finish. Also, use a vibration dampener when cutting. Otherwise, refinish according to the following instructions. Note: Whenever the brake rotor has been separated from the hub/axle flange, clean any rust or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in increased assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 1. Using the CH-42450-A - Wheel Hub Resurfacing Kit , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the CH-41013 - Rotor Resurfacing Kit , thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris. 5. Ensure that any vibration dampening attachments are securely in place. 6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces. 7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted to the lathe. 8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe. 9. Following the brake lathe manufacturer's instructions, refinish the brake rotor. 10. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). 11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. 12. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9071 * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner and wipe each friction surface using a clean shop towel to remove metal particles remaining from machining. Repeat the cleaning process if necessary to remove all metal particles. 13. Remove the brake rotor from the brake lathe. 14. Measure the assembled LRO of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). Brake Rotor Surface and Wear Inspection Brake Rotor Surface and Wear Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4) (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4))Front Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement (JH6, JH7)) and/or Rear Disc Brake Pads Replacement (JD9) (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement (JD9))Rear Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement (JH6, JH7)). 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Inspect the friction surfaces of the brake rotor for the following Braking Surface Conditions: * Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc. Heavy surface rust and/or pitting must be removed by refinishing the rotor. * Cracks and/or heat spots * Excessive blueing discoloration 4. If the friction surfaces of the brake rotor exhibit one or more of the Braking Surface Conditions, the rotor requires refinishing or replacement. 5. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the scoring depth of any grooves present on the rotor friction surfaces. 6. Compare the groove scoring depth recorded to the following specification: Brake rotor maximum allowable scoring: 1.50 mm (0.059 in) 7. If the brake rotor scoring depth exceeds the specification, or if an excessive amount of scoring is present, the rotor requires refinishing or replacement. Brake Rotor Thickness Measurement Brake Rotor Thickness Measurement Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4) (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4))Front Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement (JH6, JH7)) and/or Rear Disc Brake Pads Replacement (JD9) (See: Brake Pad/Service and Repair/Removal and Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9072 Replacement/Rear Disc Brake Pads Replacement (JD9))Rear Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement (JH6, JH7)). 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the thickness of the brake rotor at four or more points, evenly spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outer edge of the rotor, about 13 mm (1/2 in) for each measurement. 4. Compare the lowest thickness measurement recorded to the following specifications: - Brake rotor minimum allowable thickness after refinishing 37.0 mm (1.457 in) - Brake rotor discard thickness 36.50 mm (1.437 in) - Brake rotor minimum allowable thickness after refinishing 28.0 mm (1.10 in) - Brake rotor discard thickness 28.0 mm (1.10 in) - Brake rotor minimum allowable thickness after refinishing 18.5 mm (0.728 in) - Brake rotor discard thickness 18.0 mm (0.709 in) - Brake rotor minimum allowable thickness after refinishing 28.0 mm (1.102 in) - Brake rotor discard thickness 27.50 mm (1.083 in) - Brake rotor minimum allowable thickness after refinishing 29.0 mm (1.142 in) - Brake rotor discard thickness 28.50 mm (1.122 in) 5. If the lowest thickness measurement of the brake rotor is above the minimum allowable thickness after refinishing specification, the rotor may be able to be refinished, depending upon surface and wear conditions which may be present. 6. If the lowest thickness measurement of the brake rotor is at or below the minimum allowable thickness after refinishing specification, the rotor may not be refinished. 7. If the lowest thickness measurement of the brake rotor is at or below the discard thickness specification, the rotor requires replacement. Brake Rotor Thickness Variation Measurement Brake Rotor Thickness Variation Measurement Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: Any disc brake rotor that exhibits thickness variation exceeding the maximum acceptable level must be refinished or replaced. Thickness variation exceeding the maximum acceptable level can cause brake pulsation. 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4) (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4))Front Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement (JH6, JH7)) and/or Rear Disc Brake Pads Replacement (JD9) (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement (JD9))Rear Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement (JH6, JH7)). 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9073 3. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the thickness of the brake rotor at four or more points, evenly spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outer edge of the rotor, about 13 mm (1/2 in), for each measurement. 4. Calculate the difference between the highest and lowest thickness measurement recorded to obtain the amount of thickness variation. 5. Compare the thickness variation measurement to the following specifications: Brake rotor maximum allowable thickness variation: 0.025 mm (0.001 in) Brake rotor maximum allowable thickness variation: 0.018 mm (0.0007 in) Brake rotor maximum allowable thickness variation: 0.018 mm (0.0007 in) Note: Whenever a brake rotor is refinished or replaced, the assembled lateral runout (LRO) of the rotor must be measured to ensure optimum performance of the disc brakes. 6. If the brake rotor thickness variation measurement exceeds the specification, the rotor requires refinishing or replacement. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) Brake Rotor/Disc: Service and Repair Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9076 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9077 Brake Rotor/Disc: Service and Repair Front Brake Rotor Replacement (JH6, JH7) Front Brake Rotor Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9078 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9079 Brake Rotor/Disc: Service and Repair Rear Brake Rotor Replacement (JD9) Rear Brake Rotor Replacement (JD9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9080 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9081 Brake Rotor/Disc: Service and Repair Rear Brake Rotor Replacement (JH6) Rear Brake Rotor Replacement (JH6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9082 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9083 Brake Rotor/Disc: Service and Repair Rear Brake Rotor Replacement (JH7) Rear Brake Rotor Replacement (JH7) Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Release the park brake. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 4. Remove the hub and rotor assembly. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). 5. Mark the relationship of the hub to the rotor. 6. Place the hub and rotor assembly on a hydraulic press. 7. Press the wheel studs out of the hub and rotor assembly. 8. Separate the hub from the rotor. Installation Procedure 1. Align the hub and the rotor. 2. Install each of the new wheel studs into the hub and rotor assembly by performing the following: 1. Install the stud. 2. Install 4 washers to the stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9084 3. Install a lug nut to the stud with the flat side of the nut toward the washers. 4. Tighten the lug nut to draw the stud into the hub and rotor assembly. 5. Inspect the hub and rotor assembly to ensure the stud is seated completely. 6. Remove the lug nut and the washers. 3. Install the hub and rotor assembly to the vehicle. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). 4. With the engine OFF, gradually apply the brake pedal to 2/3 of its travel distance. 5. Slowly release the brake pedal. 6. Wait 15 seconds, then repeat steps 4-5 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 7. Fill the master cylinder reservoir, if necessary. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9. If the brake rotor was refinished or replaced, burnish the brake pads and rotors. Refer to Brake Pad and Rotor Burnishing (See: Brake Pad/Service and Repair/Procedures). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair Backing Plate: Service and Repair Rear Brake Backing Plate Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Brake drum maximum allowable scoring .................................................................................................................................................... 1.5 mm (0.06 in) Maximum allowable radial runout ......................................................................................................................................................... 0.06 mm (0.0024 in) Maximum allowable diameter ............................................................................................................................................................. 296.5 mm (11.673 in) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Brake Drum Diameter Measurement Brake Drum: Testing and Inspection Brake Drum Diameter Measurement Brake Drum Diameter Measurement 1. Clean the brake shoe lining contact surface of the brake drum with denatured alcohol or an equivalent brake cleaner. 2. Using a brake drum micrometer calibrated in thousands of an inch, measure and record the largest diameter of the brake drum at 4 or more points, equally spaced around the drum. Ensure that the measurements are only taken within the brake shoe lining contact area and that the micrometer is positioned the same distance from the outside edge of the drum for each measurement. 3. The maximum allowable diameter : Maximum allowable measurement 296.5 mm (11.673 in) 4. If the largest diameter measurement of the brake drum is less than the maximum allowable diameter, the drum may be able to be resurfaced, depending upon surface and wear conditions which may be present. 5. If the largest diameter measurement of the brake drum is equal to or greater than the maximum allowable measurement, the drum requires replacement. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Brake Drum Diameter Measurement > Page 9094 Brake Drum: Testing and Inspection Brake Drum Surface and Wear Inspection Brake Drum Surface and Wear Inspection Special Tools J 8001 Dial Indicator Set, or equivalent Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. With the brake drum removed, clean the braking (friction) surface of the brake drum with denatured alcohol or an equivalent approved brake cleaner. 2. Inspect the braking surface of the brake drum for the following braking surface conditions: * Heavy rust and/or pitting-Light surface rust can be removed with an abrasive disc. Heavy surface rust and/or pitting must be removed by refinishing the drum. * Cracks and/or heat spots * Excessive blueing discoloration * Missing balance weights 3. If the braking surface of the brake drum exhibits 1 or more of the braking surface conditions, the drum requires refinishing or replacement. 4. Using a brake drum micrometer calibrated in thousands of an inch, measure and record any grooves present on the drum braking surface. Ensure that the measurements are only taken within the brake shoe lining contact area. 5. Compare the groove, scoring, depth recorded to the following specification: Brake drum maximum allowable scoring 1.5 mm (0.06 in). 6. If the brake drum scoring depth exceeds the specification, or if an excessive amount of scoring is present, the drum requires refinishing or replacement. 7. Mount the brake drum on a brake lathe. 8. Mount a dial indicator, J 8001 or equivalent, and position the indicator button so it contacts the braking surface of the brake drum at a 90 degree angle, approximately 19 mm (0.75 in) from the drum's outer edge. 9. Measure and record the radial runout of the brake drum. 1. Rotate the drum until the lowest reading is displayed on the indicator dial, then zero the dial. 2. Rotate the drum until the highest reading is displayed on the dial. 10. Compare the radial runout of the brake drum to the following specification: Brake drum maximum allowable radial runout 0.06 mm (0.0024 in). 11. If the brake drum radial runout exceeds the specification, the drum requires refinishing or replacement. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures Brake Drum: Procedures Brake Drum Refinishing Special Tools * J 41013 Rotor/Drum Flange Resurfacing Kit * J 42450-A Hub Cleaning Kit Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. The brake drums do not require refinishing as part of routine brake system service. Do not refinish brake drums in an attempt to correct the following conditions: * Brake system noise (squeal, growl, groan) * Uneven and/or premature brake lining wear * Superficial or cosmetic corrosion/rust of the brake drum surface * Scoring of the brake drum surface (less than the maximum allowable specification) 2. Brake drums should only be refinished if the following conditions exist: * Excessive corrosion/rust and/or pitting * Cracks and/or heat spots * Excessive blueing discoloration * Scoring of the brake drum surface (in excess of the maximum allowable specification) * Radial runout in excess of the maximum allowable specification 3. Inspect each of the brake drums and determine if the brake drums can be refinished and remain within the maximum allowable diameter after refinish specification: 1. With the tire and wheel assemblies removed, measure the diameter of each of the brake drums. Refer to Brake Drum Diameter Measurement ( See: Testing and Inspection/Brake Drum Diameter Measurement). 2. Inspect each of the brake drums for excessive surface wear and/or radial runout. Refer to Brake Drum Surface and Wear Inspection (See: Testing and Inspection/Brake Drum Surface and Wear Inspection). 4. If the brake drums can be refinished, proceed with the rotor refinishing procedure. 5. If necessary, use the J 41013 in order to thoroughly clean any corrosion/rust from the brake drum flange. 6. Mount the brake drum to the brake lathe according to the lathe manufacturer's instructions. 7. Ensure that any vibration dampening attachments are securely in place. 8. With the brake lathe running, slowly bring in the cutting tool until it just contacts the brake drum friction surface. 9. Observe the witness mark on the brake drum. If the witness mark extends approximately three-quarters or more of the way around the brake drum surface, the brake drum is properly mounted to the lathe. 10. If the witness mark does not extend three-quarters or more of the way around the brake drum, re-mount the brake drum to the lathe. 11. Following the brake lathe manufacturer's instructions, refinish the brake drum. 12. After each successive cut, inspect the brake drum diameter. Refer to Brake Drum Diameter Measurement (See: Testing and Inspection/Brake Drum Diameter Measurement). 13. If at any time the brake drum exceeds the maximum allowable diameter after refinish specification, the brake drum must be replaced. 14. After refinishing the brake drum, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean the friction surface of the brake drum with denatured alcohol or an equivalent brake cleaner and wipe the friction surface using a clean shop towel to remove metal particles remaining from machining. Repeat the cleaning process if necessary to remove all metal particles. 15. Remove the brake drum from the brake lathe. Note: Failure to clean the corrosion from the wheel bearing flange may result in increased lateral runout of the brake drum and brake system pulsation. 16. If necessary, use the J 42450-A in order to thoroughly clean any corrosion from the wheel bearing flange. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures > Page 9097 Brake Drum: Removal and Replacement Brake Drum Replacement Special Tools J-42450-A - Wheel Hub Resurfacing Kit Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove and discard the brake drum retainers (1), if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures > Page 9098 4. Remove the brake drum (1). 5. If the brake shoes prevent the brake drum from being removed, retract the brake shoe adjuster. Refer to Drum Brake Adjustment (See: Adjustments). Installation Procedure 1. Using the J-42450-A - Wheel Hub Resurfacing Kit , remove any corrosion from the rear axle flange contact surface. 2. Install the brake drum (1). 3. Adjust the drum brakes. Refer to Drum Brake Adjustment (See: Adjustments). 4. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Replace the shoe and lining assemblies when the thickness of any lining is worn within 0.72 mm (0.030 in) of the shoe. Replace riveted shoe and lining assemblies when the lining is worn to within 0.76 mm (0.030 in) of any rivet head. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9102 Brake Shoe: Testing and Inspection Brake Shoe Inspection Inspect the linings every 9 650 km (6,000 mi) and any time the wheels are removed (tire rotation, etc.). Inspect the lining for wear by removing the plug and using the inspection hole. Replace the shoe and lining assemblies when the thickness of any lining is worn within 0.72 mm (0.030 in) of the shoe. Replace riveted shoe and lining assemblies when the lining is worn to within 0.76 mm (0.030 in) of any rivet head. Always replace shoe and lining assemblies as a complete axle set. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9103 Brake Shoe: Service and Repair Brake Shoe Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Remove the brake drum. Refer to Brake Drum Replacement (See: Brake Drum/Service and Repair/Removal and Replacement). 2. Remove the brake shoe adjuster actuator lever spring (1). 3. Remove the adjuster actuator lever (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9104 4. Spread the brake shoes apart slightly and remove the brake shoe adjuster (1). 5. Inspect and replace any missing, worn, or damaged drum brake adjuster hardware. Refer to Drum Brake Adjusting Hardware Inspection (See: Testing and Inspection/Drum Brake Adjusting Hardware Inspection). 6. Remove the brake shoe hold down springs and cups (1). Compress the spring and rotate the assembly 1/4 turn to remove from the hold down pins. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9105 7. Remove the lower brake shoe spring (1). 8. Rotate the primary brake shoe (1) outward, disengage the return spring from the brake shoe web and remove the primary brake shoe. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9106 9. Remove the brake shoe return spring. 10. Compress the park brake cable spring, disengage the park brake cable fitting end from the park brake lever and remove the secondary brake shoe (1). 11. Clean the backing plate and apply high temperature brake lubricant to the brake shoe contact surfaces of the rear brake backing plate. 12. Inspect and replace any missing, worn, or damaged drum brake hardware. Refer to Drum Brake Hardware Inspection (See: Testing and Inspection/Drum Brake Hardware Inspection). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9107 1. Compress the park brake cable spring and insert the park brake cable fitting end to the park brake on the secondary brake shoe (1). Position the secondary brake shoe to the rear brake backing plate. 2. Install the brake shoe return spring. Insert the hook end of the return spring to the brake shoe from behind the web. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9108 3. Install the primary brake (1) shoe return spring and position the primary brake shoe to the rear brake backing plate. Insert the hook end of the return spring to the brake shoe web from the outer face. 4. Install the lower brake shoe spring (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9109 5. Install the brake shoe hold down springs and cups (1). Compress the spring and rotate the assembly 1/4 turn to install to the hold down pins. 6. Disassemble, clean and lubricate the threads of the brake shoe adjuster with high temperature brake lubricant. 7. Assemble the brake shoe adjuster. 8. Spread the brake shoes apart slightly and install the brake shoe adjuster (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9110 9. Install the adjuster actuator lever (1) to the pivot pin on the primary brake shoe. 10. Install the brake shoe adjuster actuator lever spring (1). 11. Install the brake drum. Refer to Brake Drum Replacement (See: Brake Drum/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair Wheel Cylinder: Service and Repair Rear Brake Cylinder Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake Automated Bleed Procedure Less Than 3900 KG (8600 Lb) GVW Antilock Brake System Automated Bleed Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Note: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Using the scan tool, begin the automated bleed procedure. 4. Follow the instructions on the scan tool to complete the automated bleed procedure. Apply the brake pedal when instructed by the scan tool. 5. Turn the ignition OFF. 6. Remove the scan tool from the vehicle. 7. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). 9. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 10. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 11. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 12. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 13. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). 14. Drive the vehicle to exceed 13 km/h (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 15. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Greater Than/Equal to 3900 KG (8600 Lb) GVW Antilock Brake System Automated Bleed Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Note: * Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). * The automated bleed procedure must be performed when a new brake pressure modulator valve (BPMV) is installed, because the secondary circuits of the new BPMV are not prefilled with brake fluid. * The automated bleed procedure is recommended when one of the following conditions exist: * Base brake system bleeding does not achieve the desired pedal height or feel * Extreme loss of brake fluid has occurred * Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out away from the brake modulator assembly, which is then forced out at the brake corners by the pressure bleeder. Automated Bleed Procedure Caution: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9119 painted surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Repair or replace components as needed. 4. Lower the vehicle. 5. Prepare the brake bleeding equipment and the vehicle for a pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). 6. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics). 7. Install a scan tool. 8. Turn the ignition ON, with the engine OFF. 9. With the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Special Functions 6. Select Automated Bleed 10. With an assistant ready, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: * Apply the brake pedal when instructed, using moderate effort. * Ensure the pedal remains applied until instructed to release by the scan tool. * Do not exceed the time period allowed by the scan tool for having the bleeder valves open. * The bleed sequence for each corner is as follows: - Left front - Right front - Right rear - Left rear 11. Perform the automated bleed procedure as instructed by the scan tool. 12. If the automated bleed procedure is aborted, a malfunction exists. If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) to diagnose the DTC. 13. After completion of the automated bleed procedure, press and hold the brake pedal to inspect for pedal firmness. 14. If the brake pedal feels spongy, repeat the bleed procedure completely. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 17. Lower the vehicle. 18. Adjust the brake fluid level. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). 19. Road test the vehicle while confirming the brake pedal remains high and firm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9120 Brake Bleeding: Service and Repair Hydraulic Brake Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling )Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9121 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9122 Brake Bleeding: Service and Repair Hydraulic Brake Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) Special Tools * J-29532 - Diaphragm Pressure Bleeder, or equivalent * J-35589-A - Brake Pressure Bleeder Adapter Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 6. Check the brake fluid level in the J-29532 - Diaphragm Pressure Bleeder, or equivalent. Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , to the J-35589-A - Brake Pressure Bleeder Adapter. 8. Charge the J-29532 - Diaphragm Pressure Bleeder, or equivalent , air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9123 install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve, then disconnect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , from the J-35589-A - Brake Pressure Bleeder Adapter. 23. Remove the J-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to the following procedures, as appropriate: * Antilock Brake System Automated Bleed (See: )for Two-mode Hybrid vehicles * Antilock Brake System Automated Bleed (See: )for non-hybrid vehicles less than 3900 kg (8600 lb) GVW * Antilock Brake System Automated Bleed (See: )for non-hybrid vehicles greater than/equal to 3900 kg (8600 lb) GVW 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9124 Brake Bleeding: Service and Repair Hydraulic Brake Flushing Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance - oil-based substance - Layered appearance - silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (Vacuum Assist) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Hydraulic Assist) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) * Front Brake Hose Replacement (JH6, JH7) (See: Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JH6, JH7))Front Brake Hose Replacement (JD9, JF3, JF7, JG4) (See: Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JD9, JF3, JF7, JG4)) * Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4))Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4))Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JH6, JH7))Rear Brake Hose Replacement (To Caliper - JD9) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Caliper - JD9))Rear Brake Hose Replacement (Caliper - JH6, JH7) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper - JH6, JH7)) * Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) * Rear Brake Caliper Replacement (JD9) (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Less than 3900 kg (8600 lb) GVW) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9125 * Master Cylinder Replacement (Vacuum Assist) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Hydraulic Assist) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) ; also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (Vacuum Assist) (See: Brake Fluid Reservoir/Service and Repair/Master Cylinder Reservoir Replacement (Vacuum Assist))Master Cylinder Reservoir Replacement (Hydraulic Assist) (See: Brake Fluid Reservoir/Service and Repair/Master Cylinder Reservoir Replacement (Hydraulic Assist))Master Cylinder Reservoir Replacement (Two-mode Hybrid) (). Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (JH6, JH7) (See: Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JH6, JH7))Front Brake Hose Replacement (JD9, JF3, JF7, JG4) (See: Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JD9, JF3, JF7, JG4)) * Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4))Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4))Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JH6, JH7))Rear Brake Hose Replacement (To Caliper - JD9) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Caliper - JD9))Rear Brake Hose Replacement (Caliper - JH6, JH7) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper - JH6, JH7)) * Front Brake Caliper Overhaul (JH6, JH7) (See: Brake Caliper/Service and Repair/Overhaul/Front Brake Caliper Overhaul (JH6, JH7)) or Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) * Rear Brake Caliper Overhaul (JH6, JH7) (See: Brake Caliper/Service and Repair/Overhaul/Rear Brake Caliper Overhaul (JH6, JH7)) or Rear Brake Caliper Replacement (JD9) (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Less than 3900 kg (8600 lb) GVW) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canada P/N 992667) or equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Testing and Inspection Brake Caliper: Testing and Inspection Brake Caliper Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement. 4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. * For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. * For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement Brake Caliper: Removal and Replacement Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9131 Front Brake Caliper Replacement (JH6, JH7) Front Brake Caliper Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9132 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9133 Rear Brake Caliper Replacement (JD9) Rear Brake Caliper Replacement (JD9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9134 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9135 Rear Brake Caliper Replacement (JH6, JH7) Rear Brake Caliper Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9136 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9137 Front Brake Caliper Hardware Replacement (JD9, JF3, JF7, JG4) Front Brake Caliper Hardware Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9138 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9139 Front Brake Caliper Hardware Replacement (JH6, JH7) Front Brake Caliper Hardware Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9140 Rear Brake Caliper Hardware Replacement (JD9) Rear Brake Caliper Hardware Replacement (JD9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9141 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9142 Rear Brake Caliper Hardware Replacement (JH6, JH7) Rear Brake Caliper Hardware Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9143 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9144 Front Brake Caliper Bracket Replacement (JD9, JF3, JF7, JG4) Front Brake Caliper Bracket Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9145 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9146 Front Brake Caliper Bracket Replacement (JH6, JH7) Front Brake Caliper Bracket Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9147 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9148 Rear Brake Caliper Bracket Replacement (JD9) Rear Brake Caliper Bracket Replacement (JD9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9149 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9150 Rear Brake Caliper Bracket Replacement (JH6, JH7) Rear Brake Caliper Bracket Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9151 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9152 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9153 Brake Caliper: Overhaul Front Brake Caliper Overhaul (JH6, JH7) Front Brake Caliper Overhaul (JH6, JH7) Disassembly Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Remove the brake caliper. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)). 2. Drain all the brake fluid from the caliper. Note: The brake calipers use phenolic pistons that have stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9154 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9155 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered , non-lubricated compressed air. Assembly Procedure Note: When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure that the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure that the square-cut piston seal is not twisted. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9156 4. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. Note: Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9157 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 Nm (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)). Rear Brake Caliper Overhaul (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9158 Rear Brake Caliper Overhaul (JH6, JH7) Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Disassembly Procedure 1. Remove the brake caliper. Refer to Rear Brake Caliper Replacement (JD9) (See: Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)). 2. Drain all the brake fluid from the caliper. Note: The brake calipers use phenolic pistons with stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9159 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9160 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered , non-lubricated compressed air. Assembly Procedure Note: When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure the square-cut piston seal is not twisted. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9161 4. Install the boot over the end of the piston so the fold will face toward the brake caliper housing piston bore opening. Note: Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9162 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 Nm (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Refer to Rear Brake Caliper Replacement (JD9) (See: Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic Brake System: DOT 3 Hydraulic Brake Fluid (GM Part No. U.S. 12377967, in Canada 89021320). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views Brake Fluid Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 9169 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement (Non-Hybrid) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Brake Master Cylinder Pressure Sensor (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Page 9173 Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Master Cylinder Pressure Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Reservoir > Component Information > Service and Repair > Master Cylinder Reservoir Replacement (Vacuum Assist) Brake Fluid Reservoir: Service and Repair Master Cylinder Reservoir Replacement (Vacuum Assist) Master Cylinder Reservoir Replacement (Vacuum Assist) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Reservoir > Component Information > Service and Repair > Master Cylinder Reservoir Replacement (Vacuum Assist) > Page 9178 Brake Fluid Reservoir: Service and Repair Master Cylinder Reservoir Replacement (Hydraulic Assist) Master Cylinder Reservoir Replacement (Hydraulic Assist) Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). 1. Using a suitable tool, remove the brake fluid from the brake master cylinder reservoir. 2. Discard the brake fluid into an approved container. 3. Disconnect the brake fluid level indicator switch electrical connector. 4. Remove the master cylinder reservoir bolts (1). 5. Carefully lift the master cylinder reservoir (1) straight upward and remove the reservoir from the master cylinder. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Reservoir > Component Information > Service and Repair > Master Cylinder Reservoir Replacement (Vacuum Assist) > Page 9179 6. Remove the master cylinder reservoir seals (1). Installation Procedure 1. Lubricate the master cylinder reservoir seals (1) and the outer surface area of the reservoir-to-housing barrels with GM approved brake fluid from a clean, sealed brake fluid container. 2. If reinstalling the master cylinder reservoir, clean the reservoir with denatured alcohol, or equivalent and allow to dry. 3. Install the master cylinder reservoir seals to the master cylinder. Ensure the master cylinder reservoir seals are fully seated in the master cylinder body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Reservoir > Component Information > Service and Repair > Master Cylinder Reservoir Replacement (Vacuum Assist) > Page 9180 4. Lubricate the master cylinder reservoir-to-master cylinder barrels with GM approved brake fluid from a clean, sealed brake fluid container. 5. Carefully press the master cylinder reservoir (1) straight downward and install the reservoir to the master cylinder. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the master cylinder reservoir bolts (1) and tighten to 8 Nm (71 lb in). 7. Connect the brake fluid level indicator switch electrical connector. 8. Fill the master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Special Tools J 45405 Pipe Flaring Tool Kit Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Warning Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Note: When servicing the brake pipes, note the following: * If sectioning the brake pipe, use replacement pipe of the same type and outside diameter. * Use fittings of the appropriate size and type. * Only create flares of the same type or design as originally equipped on the vehicle. 1. Inspect the area of brake pipe to be repaired or replaced. 2. Release the brake pipe to be replaced from the retainers, as required. 3. Select an appropriate location to section the brake pipe, if necessary. * Allow adequate clearance in order to maneuver the J 45405 . * Avoid sectioning the brake pipe at bends or mounting points. 4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5. Add to the measurement taken the appropriate additional length required for each flare to be created. * 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe * 9.50 mm (0.374 in) for 6.35 mm (1/4 in) diameter pipe * 12.67 mm (0.499 in) for 7.94 mm (5/16 in) diameter pipe Note: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9185 6. Using the pipe cutter included in the J 45405 , carefully cut the brake pipe squarely to the measured length. 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size. 9. Strip the nylon coating from the brake pipe end to be flared, if necessary. * Select the appropriate blade on the coating stripping tool included in the J 45405 , by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. - 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe * Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers. * While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface. Note: Do not gouge the metal surface of the brake pipe. * Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges. * After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed. * Loosen the thumbwheel of the tool and remove the brake pipe. Note: Ensure that all loose remnants of the nylon coating have been removed from the brake pipe. * Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed. - 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9186 10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J 45405 . 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. 13. Loosen the die clamping screw of the J 45405 . 14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9187 15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1). 17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies. 20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it bottoms against the die cage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9188 23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J 45405 until the forming mandrel bottoms against the clamping dies. 24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve clockwise to the closed position. 27. Rotate the body of the J 45405 until it bottoms against the die cage. 28. While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the finishing cone bottoms against the dies. 29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 30. Loosen the die clamping screw and remove the dies and pipe. 31. If necessary, lightly tap the dies until the die halves separate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9189 32. Inspect the brake pipe flare for correct shape and diameter (a). * 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe * 8.57-9.27 mm (0.344-0.358 in) flare diameter for 6.35 mm (1/4 in) diameter pipe * 10.42-10.79 mm (0.410-0.425 in) flare diameter for 7.94 mm (5/16 in) diameter pipe 33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a suitable brake pipe bending tool. Note: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or vibrating components. 34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: Brake Bleeding/Service and Repair). 37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9190 Brake Hose/Line: Service and Repair Front Brake Hose Replacement (JH6, JH7) Front Brake Hose Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9191 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9192 Brake Hose/Line: Service and Repair Front Brake Hose Replacement (JD9, JF3, JF7, JG4) Front Brake Hose Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9193 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9194 Brake Hose/Line: Service and Repair Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9195 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9196 Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Special Tools J 45405 Pipe Flaring Tool Kit Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Warning Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Note: When servicing the brake pipes, note the following: * If sectioning the brake pipe, use replacement pipe of the same type and outside diameter. * Use fittings of the appropriate size and type. * Only create flares of the same type or design as originally equipped on the vehicle. 1. Inspect the area of brake pipe to be repaired or replaced. 2. Release the brake pipe to be replaced from the retainers, as required. 3. Select an appropriate location to section the brake pipe, if necessary. * Allow adequate clearance in order to maneuver the J 45405 . * Avoid sectioning the brake pipe at bends or mounting points. 4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5. Add to the measurement taken the appropriate additional length required for each flare to be created. * 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe * 9.50 mm (0.374 in) for 6.35 mm (1/4 in) diameter pipe * 12.67 mm (0.499 in) for 7.94 mm (5/16 in) diameter pipe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9197 Note: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length. 6. Using the pipe cutter included in the J 45405 , carefully cut the brake pipe squarely to the measured length. 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size. 9. Strip the nylon coating from the brake pipe end to be flared, if necessary. * Select the appropriate blade on the coating stripping tool included in the J 45405 , by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. - 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe * Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers. * While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface. Note: Do not gouge the metal surface of the brake pipe. * Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges. * After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed. * Loosen the thumbwheel of the tool and remove the brake pipe. Note: Ensure that all loose remnants of the nylon coating have been removed from the brake pipe. * Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed. - 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9198 10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J 45405 . 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. 13. Loosen the die clamping screw of the J 45405 . 14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9199 15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1). 17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies. 20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it bottoms against the die cage. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9200 23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J 45405 until the forming mandrel bottoms against the clamping dies. 24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve clockwise to the closed position. 27. Rotate the body of the J 45405 until it bottoms against the die cage. 28. While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the finishing cone bottoms against the dies. 29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 30. Loosen the die clamping screw and remove the dies and pipe. 31. If necessary, lightly tap the dies until the die halves separate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9201 32. Inspect the brake pipe flare for correct shape and diameter (a). * 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe * 8.57-9.27 mm (0.344-0.358 in) flare diameter for 6.35 mm (1/4 in) diameter pipe * 10.42-10.79 mm (0.410-0.425 in) flare diameter for 7.94 mm (5/16 in) diameter pipe 33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a suitable brake pipe bending tool. Note: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or vibrating components. 34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: Brake Bleeding/Service and Repair). 37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes. Front Brake Hose Replacement (JH6, JH7) Front Brake Hose Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9202 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9203 Front Brake Hose Replacement (JD9, JF3, JF7, JG4) Front Brake Hose Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9204 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9205 Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9206 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9207 Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9208 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9209 Rear Brake Hose Replacement (To Caliper - JD9) Rear Brake Hose Replacement (To Caliper - JD9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9210 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9211 Rear Brake Hose Replacement (Caliper - JH6, JH7) Rear Brake Hose Replacement (Caliper - JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9212 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9213 Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9214 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9215 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Hydraulic Control Assembly - Antilock Brakes: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Brake Pressure Modulator Valve Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9220 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9221 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Brake Pressure Modulator Valve Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9222 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures Brake Master Cylinder: Procedures Master Cylinder Bench Bleeding (Non-Hybrid) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Removal and Replacement/Master Cylinder Reservoir Filling). 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9227 Brake Master Cylinder: Removal and Replacement Brake Master Cylinder Reservoir Hose Replacement Brake Master Cylinder Reservoir Hose Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Note: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key. Note: During the pressure relief process, the fluid level in the master cylinder reservoir will rise. Do not remove the master cylinder reservoir cap during the pressure relief process. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Remove the brake fluid from the brake master cylinder reservoir until the level is below the reservoir supply hose fitting and discard into an approved container. 4. Disconnect the brake fluid level sensor electrical connector. 5. Disconnect the brake master cylinder reservoir return hose quick connect (1). 6. Disconnect the brake master cylinder reservoir supply hose quick connect (2). 7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 8. Remove the left front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9228 9. Remove the antilock brake system (ABS) module splash shield retainer (1). 10. Remove the ABS module splash shield bolts (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9229 11. Remove the ABS module splash shield (1). 12. Clean all dirt and debris from the brake pressure modulator valve (BPMV) assembly and the brake hose fittings. 13. Disconnect the BPMV supply hose quick connect (1). Cap the BPMV inlet port and plug the supply hose to prevent brake fluid loss and contamination. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9230 14. Disconnect the BPMV return hose quick connect (1). Cap the BPMV outlet port and plug the return hose to prevent brake fluid loss and contamination. 15. Release the supply and return hoses from the retainers and remove the hoses from the vehicle. Installation Procedure 1. Install the supply and return hoses to the vehicle and the retainers. 2. Connect the BPMV return hose quick connect (1). Ensure the return hose quick connect is fully engaged by attempting to pull the return hose from the outlet fitting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9231 3. Connect the BPMV supply hose quick connect (1). Ensure the supply hose quick connect is fully engaged by attempting to pull the supply hose from the inlet fitting. 4. Install the ABS module splash shield (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9232 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the ABS module splash shield bolts (1) and tighten to 20 Nm (15 lb ft). 6. Install the ABS module splash shield retainer (1). 7. Install the left front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 8. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9233 9. Connect the brake master cylinder reservoir return hose quick connect (1). 10. Connect the brake master cylinder reservoir supply hose quick connect (2). 11. Fill the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Master Cylinder Reservoir Filling). Master Cylinder Replacement (Vacuum Assist) Master Cylinder Replacement (Vacuum Assist) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9234 Master Cylinder Replacement (Hydraulic Assist) Master Cylinder Replacement (Hydraulic Assist) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9235 Brake Master Cylinder Adapter Replacement Brake Master Cylinder Adapter Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9236 Removal Procedure 1. Place the transmission in the PARK or NEUTRAL position. 2. Apply the park brake. Note: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 3. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 4. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 5. Remove the master cylinder nuts (1). Discard the master cylinder nuts. 6. Without disconnecting the brake pipes, release and carefully position aside the master cylinder (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9237 Support the master cylinder with heavy mechanics wire or equivalent. 7. Inspect the master cylinder seal (1) for damage and replace, if necessary. 8. Disconnect the brake master cylinder (BMC) primary piston position sensor electrical connector. 9. Remove the brake pushrod retainer bolt (1), if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9238 10. Remove the brake pushrod retainer (1). 11. Slide the stoplamp switch (1) off of the brake pedal pushrod pin while simultaneously disconnecting the brake pushrod. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9239 12. Remove the 4 brake pedal bracket nuts (1). 13. Remove the brake master cylinder adapter (1). 14. Inspect the master cylinder adapter gasket for damage and replace, if necessary. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9240 1. Install the master cylinder adapter gasket, if removed. 2. Install the brake master cylinder adapter (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 4 brake pedal bracket nuts (1) and tighten to 25 Nm (18 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9241 4. Connect the brake pedal pushrod while simultaneously installing the stoplamp switch (1). 5. Install the brake pushrod retainer (1). Rotate the brake pushrod retainer 360 degrees to ensure the retainer is fully engaged in the brake pedal pushrod pivot pin groove. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9242 6. Install the brake pushrod retainer bolt (1), if equipped and tighten to 10 Nm (89 lb in). 7. Connect the BMC primary piston position sensor electrical connector. 8. Install the master cylinder seal (1), if removed. Ensure the brake master cylinder seal is fully seated in the groove on the master cylinder housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9243 9. Position the master cylinder (1) to the master cylinder adapter. 10. Install 2 new master cylinder nuts (1) and tighten to 33 Nm (24 lb ft). 11. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics). 12. If necessary, connect a battery charger to the 12V battery. Refer to Battery Charging (See: Starting and Charging/Battery/Service and Repair/Procedures). 13. Install a scan tool to the vehicle. Note: The ignition switch must remain in the ON position with the engine OFF during this procedure. 14. Turn the ignition ON with the engine OFF. 15. Using the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9244 4. Select Electronic Brake Control Module (EBCM) 5. Select Module Setup 6. Select BMC Primary Piston Position Relearn and follow the instructions on the scan tool Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling (Non-Hybrid) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair Wheel Cylinder: Service and Repair Rear Brake Cylinder Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Service and Repair Parking Brake Actuator: Service and Repair Parking Brake Actuator Replacement (JD9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures Parking Brake Cable: Procedures Parking Brake Cable Adjuster Disabling Parking Brake Cable Adjuster Disabling Before any components of the parking brake system are serviced, the following procedure must be followed. Two technicians are required to perform this procedure, one inside the vehicle and one outside the vehicle. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Hold the pedal in the FULL upward position. 3. Pull rearward on the front park brake cable until the pedal drum (2) reaches its full reset position. 4. Insert a thin tool (1) on an upward angle through the hole in the front of the pedal assembly, past the retracted pedal drum, and into the hole in the back of the pedal assembly (3). 5. Slowly release the cable. 6. Remove the component that requires service. Parking Brake Cable Adjuster Enabling Parking Brake Cable Adjuster Enabling 1. Hold the park brake pedal in the FULL upward position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9256 2. Pull rearward on the front park brake cable until the tension is released from the tool (1) installed in the pedal assembly. 3. Remove the tool (1). 4. Slowly release the park brake cable until it returns to its original position. 5. Release the park brake pedal. 6. Lower the vehicle. 7. Apply and release the park brake pedal 3 times. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9257 Parking Brake Cable: Removal and Replacement Parking Brake Intermediate Cable Replacement (JD9, JF3, JF7) Parking Brake Intermediate Cable Replacement (JD9, JF3, JF7) Removal Procedure 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the front park brake cable (2) from the intermediate cable connector by drilling a 3 mm (1/8 in) hole through the dimple in the front to intermediate park brake cable connector (1). 5. Disconnect the left park brake cable (1) and the right park brake cable (2) from the equalizer bar (3) on the intermediate park brake cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9258 6. Remove the intermediate park brake cable. Installation Procedure 1. Connect the left park brake cable (1) and the right park brake cable (2) to the equalizer bar (3) on the intermediate park brake cable. 2. Connect the front park brake cable (2) to the intermediate cable connector. 3. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 4. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) (See: Adjustments/Parking Brake Adjustment (Drum Brake) )Parking Brake Adjustment (1500 Disc Brake) (See: Adjustments/Parking Brake Adjustment (Disc Brake))Parking Brake Adjustment (2500/3500 SRW) ()Parking Brake Adjustment (3500 DRW) (). Parking Brake Intermediate Cable Replacement (JH6, JH7) Parking Brake Intermediate Cable Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9259 Removal Procedure 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the front park brake cable (2) from the intermediate cable connector (1) by drilling a 3 mm (1/8 in) hole through the dimple in the front to intermediate park brake cable connector. 5. Disconnect the left park brake cable (2) from the intermediate cable connector (1) by drilling a 3 mm (1/8 in) hole through the dimple in the front to intermediate park brake cable connector. 6. Remove the intermediate park brake cable. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9260 1. Connect the left park brake cable (2) to the intermediate park brake cable connector (1). 2. Connect the front park brake cable (2) to the intermediate park brake cable connector (1). 3. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 4. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) (See: Adjustments/Parking Brake Adjustment (Drum Brake) )Parking Brake Adjustment (1500 Disc Brake) (See: Adjustments/Parking Brake Adjustment (Disc Brake))Parking Brake Adjustment (2500/3500 SRW) ()Parking Brake Adjustment (3500 DRW) (). Parking Brake Rear Cable Replacement - Left Side (JD9) Parking Brake Rear Cable Replacement - Left Side (JD9) Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9261 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the left park brake cable (1) from the intermediate cable equalizer bar (2). 5. Release the left park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Remove the park brake cable clip bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9262 7. Release the park brake cable from the rear axle bracket by compressing the locking tabs and pulling the park brake cable conduit (1) rearward. 8. Disconnect the park brake cable eye (2) from the park brake actuator lever. 9. Remove the park brake cable assembly from the vehicle. Installation Procedure 1. Connect the left park brake cable eye (2) to the park brake actuator lever. 2. Install the park brake cable to the rear axle bracket by pulling the cable conduit (1) rearward and inserting the cable conduit into the rear axle bracket. Ensure the locking tabs on the cable conduit are fully engaged into the rear axle bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9263 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the park brake cable clip bolt. Tighten the bolt to 22 Nm (16 lb ft). 4. Connect the left rear park brake cable (1) to the intermediate cable equalizer bar (2). 5. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 6. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 7. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) (See: Adjustments/Parking Brake Adjustment (Drum Brake) )Parking Brake Adjustment (1500 Disc Brake) (See: Adjustments/Parking Brake Adjustment (Disc Brake))Parking Brake Adjustment (2500/3500 SRW) ()Parking Brake Adjustment (3500 DRW) (). Parking Brake Rear Cable Replacement - Left Side (JF3, JF7, JG4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9264 Parking Brake Rear Cable Replacement - Left Side (JF3, JF7, JG4) Tools Required J 37043 Park Brake Cable Release Tool Removal Procedure 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the left park brake cable (1) from the intermediate cable equalizer bar (2). 5. Release the left park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Remove the park brake cable from the cable guides. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9265 7. Remove the brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). 8. Using the J 37043 (1), remove the park brake cable from the backing plate. 9. Remove the park brake cable assembly from the vehicle. Installation Procedure 1. Install the park brake cable assembly into the backing plate. 2. Install the brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). 3. Install the park brake cable to the cable guides. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9266 4. Connect the left rear park brake cable (1) to the intermediate cable equalizer bar (2). 5. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 6. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 7. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) (See: Adjustments/Parking Brake Adjustment (Drum Brake) )Parking Brake Adjustment (1500 Disc Brake) (See: Adjustments/Parking Brake Adjustment (Disc Brake))Parking Brake Adjustment (2500/3500 SRW) ()Parking Brake Adjustment (3500 DRW) (). Parking Brake Rear Cable Replacement - Left Side (JH6, JH7) Parking Brake Rear Cable Replacement - Left Side (JH6, JH7) Removal Procedure 1. Release the park brake. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9267 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the left park brake cable from the intermediate cable connector (1) by drilling a 3 mm (1/8 in) hole through the dimple in the intermediate park brake cable connector. 5. Release the left park brake cable from the equalizer (3) by compressing the locking tabs on the cable conduit (2) and pulling the cable rearward. 6. Remove the park brake cable clip bolt. 7. Disconnect the park brake cable eye (1) from the park brake actuator lever (2). 8. Remove the park brake cable (3) from the bracket by pulling the cable conduit rearward to compress the spring and sliding the cable conduit out of the bracket. 9. Remove the park brake cable assembly from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9268 1. Connect the left park brake cable eye (1) to the park brake actuator lever (2). 2. Install the park brake cable to the rear axle bracket by pulling the cable conduit (3) rearward to compress the spring and inserting the cable conduit into the rear axle bracket. Ensure the locking tabs on the cable conduit are fully engaged into the rear axle bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the park brake cable clip bolt and tighten to 22 Nm (16 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9269 4. Insert the park brake cable conduit (2) into the equalizer (3). Ensure the locking tabs on the cable conduit are fully engaged into the equalizer. 5. Connect the left rear park brake cable to the intermediate cable connector (1). 6. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 7. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) (See: Adjustments/Parking Brake Adjustment (Drum Brake) )Parking Brake Adjustment (1500 Disc Brake) (See: Adjustments/Parking Brake Adjustment (Disc Brake))Parking Brake Adjustment (2500/3500 SRW) ()Parking Brake Adjustment (3500 DRW) (). Parking Brake Rear Cable Replacement - Right Side (JD9) Parking Brake Rear Cable Replacement - Right Side (JD9) Removal Procedure 1. Release the park brake. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9270 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the right park brake cable (1) from the intermediate cable equalizer bar (2). 5. Release the right park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Release the park brake cable (1) from the rear axle housing cover clip. 7. Remove the park brake cable clip bolt (2). 8. Release the park brake cable from the rear axle bracket by compressing the locking tabs and pulling the park brake cable conduit (1) rearward. 9. Disconnect the park brake cable eye (2) from the park brake actuator lever. 10. Remove the park brake cable assembly from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9271 1. Connect the right park brake cable eye (2) to the park brake actuator lever. 2. Install the park brake cable to the rear axle bracket by pulling the cable conduit (1) rearward and inserting the cable conduit into the rear axle bracket. Ensure the locking tabs on the cable conduit are fully engaged into the rear axle bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the park brake cable clip bolt (2). Tighten the bolt to 22 Nm (16 lb ft). 4. Connect the park brake cable (1) to the rear axle housing cover clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9272 5. Connect the right rear park brake cable (1) to the intermediate cable equalizer bar (2). 6. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 7. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 8. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) (See: Adjustments/Parking Brake Adjustment (Drum Brake) )Parking Brake Adjustment (1500 Disc Brake) (See: Adjustments/Parking Brake Adjustment (Disc Brake))Parking Brake Adjustment (2500/3500 SRW) ()Parking Brake Adjustment (3500 DRW) (). Parking Brake Rear Cable Replacement - Right Side (JF3, JF7, JG4) Parking Brake Rear Cable Replacement - Right Side (JF3, JF7, JG4) Special Tools J 37043 Park Brake Cable Release Tool Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9273 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the right park brake cable (1) from the intermediate cable equalizer bar (2). 5. Release the right park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Release the park brake cable (1) from the rear axle housing cover clip. 7. Remove the park brake cable clip bolt (2). 8. Remove the park brake cable from the cable guides. 9. Remove the brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9274 10. Using the J 37043 (1), remove the park brake cable from the backing plate. 11. Remove the park brake cable from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9275 1. Install the park brake cable to the vehicle. 2. Install the brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). Ensure the locking tabs on the cable conduit are fully engaged into the rear axle bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the park brake cable clip bolt (2). Tighten the bolt to 22 Nm (16 lb ft). 4. Connect the park brake cable (1) to the rear axle housing cover clip. 5. Install the park brake cable to the cable guides. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9276 6. Connect the right rear park brake cable (1) to the intermediate cable equalizer bar (2). 7. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 8. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 9. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) (See: Adjustments/Parking Brake Adjustment (Drum Brake) )Parking Brake Adjustment (1500 Disc Brake) (See: Adjustments/Parking Brake Adjustment (Disc Brake))Parking Brake Adjustment (2500/3500 SRW) ()Parking Brake Adjustment (3500 DRW) (). Parking Brake Rear Cable Replacement - Right Side (JH6, JH7) Parking Brake Rear Cable Replacement - Right Side (JH6, JH7) Removal Procedure 1. Release the park brake. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9277 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the right park brake cable from the equalizer (1). 5. Release the right park brake cable from the frame bracket by compressing the locking tabs on the cable conduit (2) and pulling the cable rearward. 6. Release the park brake cable (1) from the rear axle housing cover clip. 7. Remove the park brake cable clip bolt (2). 8. Disconnect the park brake cable eye (3) from the park brake actuator lever (2). 9. Remove the park brake cable from the bracket by pulling the cable conduit (1) rearward to compress the spring and sliding the cable conduit out of the bracket. 10. Remove the park brake cable assembly from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9278 1. Connect the right park brake cable eye (3) to the park brake actuator lever (2). 2. Install the park brake cable to the rear axle bracket by pulling the cable conduit (1) rearward to compress the spring and inserting the cable conduit into the rear axle bracket. 3. Connect the park brake cable (1) to the rear axle housing cover clip. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the park brake cable clip bolt (2) and tighten to 22 Nm (16 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9279 5. Insert the park brake cable conduit (2) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 6. Connect the right rear park brake cable to the equalizer (1). 7. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 8. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) (See: Adjustments/Parking Brake Adjustment (Drum Brake) )Parking Brake Adjustment (1500 Disc Brake) (See: Adjustments/Parking Brake Adjustment (Disc Brake))Parking Brake Adjustment (2500/3500 SRW) ()Parking Brake Adjustment (3500 DRW) (). Parking Brake Cable Guide Replacement Parking Brake Cable Guide Replacement Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9280 3. Remove the park brake cable guide bolt from the frame. 4. Remove the park brake cable guide. 5. Remove the park brake cable guide from the park brake cable. Installation Procedure 1. Install the park brake cable guide to the park brake cable. 2. Install the park brake cable guide. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the park brake cable guide bolt to the frame and tighten to 12 Nm (106 lb in). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair Parking Brake Lever: Service and Repair Parking Brake Lever Pedal Assembly Replacement Removal Procedure Note: The following service procedure includes the removal of the front park brake cable. The front park brake cable is NOT serviced separately, but serviced with the park brake pedal assembly. 1. Remove the left side hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Hinge Pillar Trim Panel Replacement). 2. Disconnect the park brake warning lamp electrical connector. 3. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Parking Brake Cable/Service and Repair/Procedures/Parking Brake Cable Adjuster Disabling). 4. Remove the bolt and disconnect the park brake pedal release handle from the instrument panel. 5. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 7. Disconnect the front park brake cable from the intermediate cable connector by drilling a 3 mm (1/8 in) hole through the dimple in the front to intermediate park brake cable connector. 8. Release the front park brake cable from the frame by depressing the locking tabs. 9. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 9284 10. Remove the park brake lever mounting nuts. 11. Position the floor carpet to expose the park brake cable pass-through grommet. 12. Release the park brake cable pass-through grommet from the vehicle floor. 13. Remove the park brake lever and front cable from the vehicle. Installation Procedure Note: Ensure the grommet for the front park brake cable is properly seated in the front floor panel. 1. Insert the front brake cable through the hole in the front floor panel and seat the pass-through grommet. 2. Position the floor carpet to the floor pan. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 9285 3. Position the park brake pedal assembly on the side panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install and finger tighten the mounting nuts. Tighten the nuts to 25 Nm (18 lb ft). 5. Connect the park brake warning lamp connection. 6. Install the park brake release handle to the instrument panel. 7. Install the park brake release handle bolt and tighten to 9 Nm (80 lb in). 8. Install the hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Hinge Pillar Trim Panel Replacement). 9. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 10. Raise the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 9286 11. Install the front park brake cable to the frame and press the retainer into place. 12. Connect the front park brake cable to the front to intermediate park brake cable connector. 13. Lower the vehicle. 14. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Parking Brake Cable/Service and Repair/Procedures/Parking Brake Cable Adjuster Enabling). 15. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) (See: Adjustments/Parking Brake Adjustment (Drum Brake) )Parking Brake Adjustment (1500 Disc Brake) (See: Adjustments/Parking Brake Adjustment (Disc Brake))Parking Brake Adjustment (2500/3500 SRW) ()Parking Brake Adjustment (3500 DRW) (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Parking Brake Shoe Replacement (JD9) Parking Brake Shoe: Service and Repair Parking Brake Shoe Replacement (JD9) Parking Brake Shoe Replacement (JD9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Parking Brake Shoe Replacement (JD9) > Page 9291 Parking Brake Shoe: Service and Repair Parking Brake Shoe Replacement (JH6, JH7) Parking Brake Shoe Replacement (JH6, JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Parking Brake Shoe Replacement (JD9) > Page 9292 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams > Page 9296 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams > Page 9297 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Diagrams Brake Booster Vacuum Sensor: Diagrams Component Connector End Views Brake Booster Vacuum Sensor (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Diagrams > Page 9302 Brake Booster Vacuum Sensor: Service and Repair Power Brake Booster Vacuum Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Power Brake Booster Replacement (Non-Adjustable Pedals) Hydraulic Brake Booster: Service and Repair Power Brake Booster Replacement (Non-Adjustable Pedals) Power Brake Booster Replacement (Non-Adjustable Pedals) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Power Brake Booster Replacement (Non-Adjustable Pedals) > Page 9307 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Power Brake Booster Replacement (Non-Adjustable Pedals) > Page 9308 Hydraulic Brake Booster: Service and Repair Power Brake Booster Replacement (Adjustable Pedals) Power Brake Booster Replacement (Adjustable Pedals) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Power Brake Booster Replacement (Non-Adjustable Pedals) > Page 9309 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster Pump > Component Information > Service and Repair Hydraulic Brake Booster Pump: Service and Repair Power Brake Booster Pump Fluid Accumulator Replacement (Non-Hybrid) Special Tools J-26889 - Accumulator Piston Compressor Removal Procedure Warning The accumulator contains compressed gas. Always use the proper tools and follow the recommended procedures or personal injury may result. Do not apply heat to accumulator. Do not attempt to repair an inoperative accumulator. Always replace an inoperative accumulator with a new one. Dispose of an inoperative accumulator by drilling a 1.5 mm (1/16 in) diameter hole through the end of the accumulator can, opposite the O-ring. Warning Push rod removal is not recommended. Improper staking of the push rod to the Hydroboost reaction piston can result in a loss of brakes. If the rod or seals require service, the entire unit must be replaced. 1. Apply the park brake and block the wheels. 2. Depress brake pedal at least 10 times in order to relieve pressure in the accumulator. 3. Remove the master cylinder from the hydraulic booster. Refer to Master Cylinder Replacement (Vacuum Assist) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Hydraulic Assist) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement). 4. Place the J-26889 - Accumulator Piston Compressor over the end of the accumulator. 5. Install the nut on the stud. 6. Depress the accumulator with a C-clamp. If the accumulator does not move with moderate pressure, remove the C-clamp and depress the brake pedal ten times in order to relieve pressure in the accumulator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster Pump > Component Information > Service and Repair > Page 9313 7. Rotate the retaining ring (2) until either end of the ring is under the access hole (1). 8. Depress and hold the retaining ring (2) with a small tool inserted into the access hole (1). 9. Remove the accumulator retainer ring (1) using a small hook shaped tool. 10. Release the C-clamp. 11. Remove the nut from the stud. 12. Remove the J-26889 Compressor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster Pump > Component Information > Service and Repair > Page 9314 13. Remove the accumulator (2) and the O-ring seal (3). Installation Procedure 1. Lubricate all of the seals and the metal friction points with power steering fluid. 2. Install the accumulator (2) and the O-ring seal (3). 3. Place the J-26889 - Compressor over the end of the accumulator. 4. Install the nut on the stud. 5. Depress the accumulator with a C-clamp. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster Pump > Component Information > Service and Repair > Page 9315 6. Install the accumulator retainer ring (1). 7. Release the C-clamp. 8. Remove the nut from the stud. 9. Remove the J-26889 - Compressor. 10. Install the master cylinder to the hydraulic booster. Refer to Master Cylinder Replacement (Vacuum Assist) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Hydraulic Assist) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement). 11. Release the park brake and unblock the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Service and Repair Hydraulic Fluid Accumulator: Service and Repair Power Brake Booster Pump Fluid Accumulator Disposal Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Vacuum Brake Booster Replacement (Without JF4) Vacuum Brake Booster: Service and Repair Power Vacuum Brake Booster Replacement (Without JF4) Power Vacuum Brake Booster Replacement (Without JF4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Vacuum Brake Booster Replacement (Without JF4) > Page 9323 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Vacuum Brake Booster Replacement (Without JF4) > Page 9324 Vacuum Brake Booster: Service and Repair Power Vacuum Brake Booster Replacement (With JF4) Power Vacuum Brake Booster Replacement (With JF4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Vacuum Brake Booster Replacement (Without JF4) > Page 9325 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Service and Repair Vacuum Pump: Service and Repair Power Brake Booster Vacuum Check Valve and Hose Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9334 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9335 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9336 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9337 Trailer Brake Control Module: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9338 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9339 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9340 Trailer Brake Control Module: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 except 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9341 Trailer Brake Control Module (JL1 with 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9342 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9343 Fuel Pump/Trailer Brake Control Module (Gas with JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9344 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9345 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement > Page 9348 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement (1500) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: The trailer brake control module is integral to the fuel pump flow control module. 2. Remove the fuel pump flow control module (1). Refer to Fuel Pump Flow Control Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement > Page 9349 1. Install the fuel pump flow control module (1). Refer to Fuel Pump Flow Control Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. If installing a new trailer brake control module, program the module. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams Electronic Brake Control Module: Diagrams Component Connector End Views Electronic Brake Control Module (EBCM) (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9354 Electronic Brake Control Module (EBCM) (JF3 or JF7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9355 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9356 Electronic Brake Control Module (EBCM) (JH6 or JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9357 Electronic Brake Control Module (EBCM) (JL4 except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9358 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9359 Electronic Brake Control Module (EBCM) (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9360 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9361 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Electronic Brake Control Module: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Electronic Brake Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9364 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9365 Electronic Brake Control Module: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Electronic Brake Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9370 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9371 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9372 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9373 Trailer Brake Control Module: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9374 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9375 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9376 Trailer Brake Control Module: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 except 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9377 Trailer Brake Control Module (JL1 with 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9378 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9379 Fuel Pump/Trailer Brake Control Module (Gas with JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9380 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9381 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement > Page 9384 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement (1500) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: The trailer brake control module is integral to the fuel pump flow control module. 2. Remove the fuel pump flow control module (1). Refer to Fuel Pump Flow Control Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement > Page 9385 1. Install the fuel pump flow control module (1). Refer to Fuel Pump Flow Control Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. If installing a new trailer brake control module, program the module. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams Brake Booster Vacuum Sensor: Diagrams Component Connector End Views Brake Booster Vacuum Sensor (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams > Page 9390 Brake Booster Vacuum Sensor: Service and Repair Power Brake Booster Vacuum Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views Brake Fluid Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 9394 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement (Non-Hybrid) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Brake Master Cylinder Pressure Sensor (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Page 9398 Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Master Cylinder Pressure Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Service and Repair Braking Sensor/Switch: Service and Repair Brake Master Cylinder Primary Piston Position Sensor Replacement Removal Procedure Note: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Disconnect the brake master cylinder (BMC) primary piston position sensor electrical connector. 4. Remove the 2 BMC primary piston position sensor screws (1). 5. Remove the primary piston position sensor (2). Tilt the rear of the position sensor downward and remove the sensor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Service and Repair > Page 9402 1. Install the BMC primary piston position sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 2 BMC primary piston position sensor screws (1) and tighten to 10 Nm (89 lb in). 3. Connect the primary piston position sensor electrical connector. 4. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics). 5. If necessary, connect a battery charger to the 12V battery. Refer to Battery Charging (See: Starting and Charging/Battery/Service and Repair/Procedures) 6. Install a scan tool to the vehicle. Note: The ignition switch must remain in the ON position with the engine OFF during this procedure. 7. Turn the ignition ON with the engine OFF. 8. Using the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Module Setup 6. Select BMC Primary Piston Position Relearn and follow the instructions on the scan tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams Lateral Accelerometer: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams > Page 9406 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams > Page 9407 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Page 9411 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Page 9412 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams Wheel Speed Sensor: Diagrams Component Connector End Views Wheel Speed Sensor (WSS) - Left Front (10 Series) Wheel Speed Sensor (WSS) - Left Front (except 10 Series) Wheel Speed Sensor (WSS) - Left Rear (JL4 or HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 9416 Wheel Speed Sensor (WSS) - Right Front (10 Series) Wheel Speed Sensor (WSS) - Right Front (except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 9417 Wheel Speed Sensor (WSS) - Right Rear (JL4 or HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Front Wheel Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9420 Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Front Wheel Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9421 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9422 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9423 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9424 Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9425 2. Disconnect the wheel speed sensor electrical connector (1). 3. Release the wheel speed sensor electrical connector and sensor harness clips (2) from the inboard frame rail. 4. Remove the wheel speed sensor bolt (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9426 5. Remove the wheel speed sensor (1) from the rear axle. Installation Procedure 1. Install the wheel speed sensor (1) to the rear axle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9427 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the wheel speed sensor bolt (1) and tighten to 9 Nm (80 lb in). 3. Connect the wheel speed sensor electrical connector (1). 4. Install the wheel speed sensor electrical connector and sensor harness clips (2) to the inboard frame rail. 5. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9428 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Ring Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Ring Replacement Special Tools * J-8092 - Driver Handle * J-21128 - Axle Pinion Oil Seal Installer * J-23690 - Bearing Installer * J-2619-01 - Slide Hammer * J-45857 - Tone Wheel and/or Bearing Remover * J-45860 - Tone Ring Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). 4. Remove the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 5. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 6. Remove the axle shaft seal, the bearing and the wheel speed sensor ring from the axle housing using the J-2619-01 - Slide Hammer (1) and the J-45857 - Tone Wheel and/or Bearing Remover (2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9429 1. Install the wheel speed sensor ring using the J-45860 - Tone Ring Installer (1) and the J-8092 Driver Handle (2). 2. Drive the wheel speed sensor ring into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft bearing using the J-23690 - Bearing Installer (1) and the J-8092 - Driver Handle (2). 4. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9430 5. Install the axle shaft seal using the J-21128 - Axle Pinion Oil Seal Installer. 6. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 7. Install the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 8. Install the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 9. Install the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). 10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 11. Fill the rear axle. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement). 12. Lower the vehicle. Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Ring Replacement Removal Procedure Note: The wheel speed sensor ring is integral to the wheel hub and must be replaced as an assembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 4. Remove the rear axle hub. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). Installation Procedure 1. Install the rear axle hub. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). 2. Install the rear brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9431 Brake Rotor Replacement (JH7)). 3. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams Yaw Rate Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams > Page 9435 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams > Page 9436 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Yaw Rate Sensor: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9439 Yaw Rate Sensor: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams > Page 9445 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Battery/Battery Cable/Negative/Service and Repair )Battery Negative Cable Replacement (V8) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Battery/Battery Cable/Negative/Service and Repair). 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams > Page 9446 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Battery/Battery Cable/Negative/Service and Repair )Battery Negative Cable Replacement (V8) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 9452 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 9453 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note: The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 9454 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations Auxiliary Battery Relay: Locations Harness Routing Views Auxiliary Battery Harness Routing (TP2) 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 9459 Auxiliary Battery Relay: Diagrams Component Connector End Views Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X2 (TP2) Auxiliary Battery Relay X3 (TP2) Auxiliary Battery Run Relay (TP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 9460 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 9461 Auxiliary Battery Relay: Service and Repair Auxiliary Battery Relay Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Battery/Service Precautions). 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). 2. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. 3. Remove the auxiliary battery positive cable nut (6) from the battery relay stud. 4. Remove the auxiliary battery positive cable from the auxiliary battery relay. 5. Disconnect the auxiliary battery positive cable electrical connector (1) from the battery relay. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 9462 6. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. 7. Remove the auxiliary battery positive cable nut (4) from the battery relay stud. 8. Remove the auxiliary battery positive cable from the auxiliary battery relay. 9. Remove the auxiliary battery relay nuts and relay. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the auxiliary battery relay and nuts and tighten to 9 Nm (80 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 9463 2. Install the auxiliary battery positive cable to the auxiliary battery relay. 3. Install the auxiliary battery positive cable nut (4) to the battery relay stud and tighten to 9 Nm (80 lb in). 4. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 5. Connect the auxiliary battery positive cable electrical connector (1) to the battery relay. 6. Install the auxiliary battery positive cable to the auxiliary battery relay. 7. Install the auxiliary battery positive cable nut (6) to the battery relay stud and tighten to 9 Nm (80 lb in). 8. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 9. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9467 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9468 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9469 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9470 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9471 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9472 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9473 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Auxiliary Battery Relay > Component Information > Locations Auxiliary Battery Relay: Locations Harness Routing Views Auxiliary Battery Harness Routing (TP2) 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Auxiliary Battery Relay > Component Information > Locations > Page 9478 Auxiliary Battery Relay: Diagrams Component Connector End Views Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X2 (TP2) Auxiliary Battery Relay X3 (TP2) Auxiliary Battery Run Relay (TP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Auxiliary Battery Relay > Component Information > Locations > Page 9479 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Auxiliary Battery Relay > Component Information > Locations > Page 9480 Auxiliary Battery Relay: Service and Repair Auxiliary Battery Relay Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery Cable/Negative/Service and Repair). 2. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. 3. Remove the auxiliary battery positive cable nut (6) from the battery relay stud. 4. Remove the auxiliary battery positive cable from the auxiliary battery relay. 5. Disconnect the auxiliary battery positive cable electrical connector (1) from the battery relay. 6. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Auxiliary Battery Relay > Component Information > Locations > Page 9481 7. Remove the auxiliary battery positive cable nut (4) from the battery relay stud. 8. Remove the auxiliary battery positive cable from the auxiliary battery relay. 9. Remove the auxiliary battery relay nuts and relay. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the auxiliary battery relay and nuts and tighten to 9 Nm (80 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Auxiliary Battery Relay > Component Information > Locations > Page 9482 2. Install the auxiliary battery positive cable to the auxiliary battery relay. 3. Install the auxiliary battery positive cable nut (4) to the battery relay stud and tighten to 9 Nm (80 lb in). 4. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 5. Connect the auxiliary battery positive cable electrical connector (1) to the battery relay. 6. Install the auxiliary battery positive cable to the auxiliary battery relay. 7. Install the auxiliary battery positive cable nut (6) to the battery relay stud and tighten to 9 Nm (80 lb in). 8. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 9. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) Negative: Service and Repair Battery Negative Cable Disconnection and Connection (Single Battery) Battery Negative Cable Disconnection and Connection (Single Battery) Disconnect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Open the hood. 4. Loosen the negative cable nut (1). 5. Reposition the negative battery cable away from the battery. Connect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). Note: Clean any existing corrosion from the battery terminal and the battery cable end. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9488 1. Position the negative battery cable to the battery. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the negative battery cable onto the battery terminal. 3. Tighten the negative cable clamp nut (1) to 5 Nm (44 lb in). 4. Close the hood. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9489 Negative: Service and Repair Battery Negative Cable Disconnection and Connection (Dual Batteries) Battery Negative Cable Disconnection and Connection (Dual Batteries) Disconnect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Open the hood. 4. Loosen the primary battery negative cable clamp nut (1). 5. Remove and reposition the primary battery negative cable, away from the battery. 6. Loosen the auxiliary battery negative clamp nut (1). 7. Remove the auxiliary battery negative cable (2) from the auxiliary battery negative post. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9490 8. Reposition the auxiliary negative battery cable away from the battery. Connect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). Note: Clean any existing corrosion from the battery terminal and the battery cable end. 1. Install the auxiliary battery negative cable (2) onto the auxiliary battery negative post. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the auxiliary battery negative cable clamp nut (2) to 7.5 Nm (66 lb in). 3. Install the primary battery negative cable onto the primary battery negative post. 4. Tighten the primary battery negative cable clamp nut (1) to 5 Nm (44 lb in). 5. Close the hood. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9491 Negative: Service and Repair Battery Negative Cable Disconnection and Connection (Auxiliary Battery) Battery Negative Cable Disconnection and Connection (Auxiliary Battery) Disconnect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Open the hood. 4. Loosen the primary battery negative cable clamp nut (1). 5. Remove the primary battery negative cable from the primary battery negative post. 6. Reposition the primary battery negative cable away from the battery. 7. Loosen the auxiliary battery negative cable clamp nut (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9492 8. Loosen the auxiliary battery negative cable nut (3). 9. Remove the auxiliary battery negative cable (2) from the auxiliary battery negative post. 10. Reposition the auxiliary battery negative cable away from the battery. Connect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). Note: Clean any existing corrosion from the battery terminal and the battery cable end. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the auxiliary battery negative cable (2) onto the auxiliary battery negative post. 2. Tighten the auxiliary battery negative cable clamp nut (1) to 7.5 Nm (66 lb in). 3. Install the primary battery negative cable onto the primary battery negative post. 4. Tighten the primary battery negative cable clamp nut (1) to 5 Nm (44 lb in). 5. Close the hood. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9493 Negative: Service and Repair Battery Negative Cable REPLACEMENT Battery Negative Cable Replacement (V8) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: )Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: )Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: ). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 3. Disconnect the engine harness electrical connector (1) from the battery current sensor. 4. Remove the battery current sensor (3) clip from the battery tray, if equipped with a battery current sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9494 5. Remove the negative battery cable stud (1) from the front of the right cylinder head. 6. Remove the negative battery cable terminal (2) from the cylinder head. 7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 8. Remove the forward lamp wiring harness ground bolt (1). 9. Remove the forward lamp wiring harness terminal (2) from the frame. 10. Remove the negative battery cable terminal (3) out through the opening between the radiator support and frame. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9495 11. Remove the negative battery cable clip (2) from the chassis harness. 12. Lower the vehicle. 13. Remove the negative battery cable clip (1) from the right wheelhouse liner. 14. Remove the negative battery cable from the vehicle, if equipped without a battery current sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9496 15. Remove the negative battery cable from the vehicle, if equipped with a battery current sensor. 16. If replacing the negative battery cable, remove the battery current sensor, if equipped. Refer to Battery Current Sensor Replacement (See: Battery Current Sensor/Service and Repair). Installation Procedure 1. If the negative battery cable was replaced, install the battery current sensor, if equipped. Refer to Battery Current Sensor Replacement (See: Battery Current Sensor/Service and Repair). 2. Install the negative battery cable to the vehicle, if equipped with a battery current sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9497 3. Install the negative battery cable to the vehicle, if equipped without a battery current sensor. 4. Ensure that the engine harness terminal (3) is position behind the negative battery terminal (2). 5. Position the negative battery cable terminal (2) to the cylinder head. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the negative battery cable stud (1) to the front of the right cylinder head and tighten to 25 Nm (18 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9498 7. Install the negative battery cable clip (1) to the right wheelhouse liner. 8. Raise the vehicle. 9. Install the negative battery cable clip (2) to the chassis harness. 10. Route the negative battery cable terminal (3) through the opening between the radiator support and frame. 11. Ensure that the negative battery cable is positioned behind the forward lamp harness. 12. Install the forward lamp wiring harness terminal (2) to the frame. Ensure that the anti-rotation tab is inserted into the hole in the frame. 13. Install the forward lamp wiring harness ground bolt (1) and tighten to 25 Nm (18 lb ft). 14. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9499 15. Install the battery current sensor (3) clip to the battery tray, if equipped with a battery current sensor. 16. Connect the engine harness electrical connector (1) to the battery current sensor. 17. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: )Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: )Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: ). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9500 Negative: Service and Repair Battery Negative Cable Disconnection and Connection (Single Battery) Battery Negative Cable Disconnection and Connection (Single Battery) Disconnect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Open the hood. 4. Loosen the negative cable nut (1). 5. Reposition the negative battery cable away from the battery. Connect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). Note: Clean any existing corrosion from the battery terminal and the battery cable end. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9501 1. Position the negative battery cable to the battery. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the negative battery cable onto the battery terminal. 3. Tighten the negative cable clamp nut (1) to 5 Nm (44 lb in). 4. Close the hood. Battery Negative Cable Disconnection and Connection (Dual Batteries) Battery Negative Cable Disconnection and Connection (Dual Batteries) Disconnect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Turn off all the lamps and accessories. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9502 2. Turn the ignition OFF. 3. Open the hood. 4. Loosen the primary battery negative cable clamp nut (1). 5. Remove and reposition the primary battery negative cable, away from the battery. 6. Loosen the auxiliary battery negative clamp nut (1). 7. Remove the auxiliary battery negative cable (2) from the auxiliary battery negative post. 8. Reposition the auxiliary negative battery cable away from the battery. Connect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). Note: Clean any existing corrosion from the battery terminal and the battery cable end. 1. Install the auxiliary battery negative cable (2) onto the auxiliary battery negative post. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9503 2. Tighten the auxiliary battery negative cable clamp nut (2) to 7.5 Nm (66 lb in). 3. Install the primary battery negative cable onto the primary battery negative post. 4. Tighten the primary battery negative cable clamp nut (1) to 5 Nm (44 lb in). 5. Close the hood. Battery Negative Cable Disconnection and Connection (Auxiliary Battery) Battery Negative Cable Disconnection and Connection (Auxiliary Battery) Disconnect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9504 3. Open the hood. 4. Loosen the primary battery negative cable clamp nut (1). 5. Remove the primary battery negative cable from the primary battery negative post. 6. Reposition the primary battery negative cable away from the battery. 7. Loosen the auxiliary battery negative cable clamp nut (1). 8. Loosen the auxiliary battery negative cable nut (3). 9. Remove the auxiliary battery negative cable (2) from the auxiliary battery negative post. 10. Reposition the auxiliary battery negative cable away from the battery. Connect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). Note: Clean any existing corrosion from the battery terminal and the battery cable end. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9505 1. Install the auxiliary battery negative cable (2) onto the auxiliary battery negative post. 2. Tighten the auxiliary battery negative cable clamp nut (1) to 7.5 Nm (66 lb in). 3. Install the primary battery negative cable onto the primary battery negative post. 4. Tighten the primary battery negative cable clamp nut (1) to 5 Nm (44 lb in). 5. Close the hood. Battery Negative Cable REPLACEMENT Battery Negative Cable Replacement (V8) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: )Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: )Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: ). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9506 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 3. Disconnect the engine harness electrical connector (1) from the battery current sensor. 4. Remove the battery current sensor (3) clip from the battery tray, if equipped with a battery current sensor. 5. Remove the negative battery cable stud (1) from the front of the right cylinder head. 6. Remove the negative battery cable terminal (2) from the cylinder head. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9507 7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 8. Remove the forward lamp wiring harness ground bolt (1). 9. Remove the forward lamp wiring harness terminal (2) from the frame. 10. Remove the negative battery cable terminal (3) out through the opening between the radiator support and frame. 11. Remove the negative battery cable clip (2) from the chassis harness. 12. Lower the vehicle. 13. Remove the negative battery cable clip (1) from the right wheelhouse liner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9508 14. Remove the negative battery cable from the vehicle, if equipped without a battery current sensor. 15. Remove the negative battery cable from the vehicle, if equipped with a battery current sensor. 16. If replacing the negative battery cable, remove the battery current sensor, if equipped. Refer to Battery Current Sensor Replacement (See: Battery Current Sensor/Service and Repair). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9509 1. If the negative battery cable was replaced, install the battery current sensor, if equipped. Refer to Battery Current Sensor Replacement (See: Battery Current Sensor/Service and Repair). 2. Install the negative battery cable to the vehicle, if equipped with a battery current sensor. 3. Install the negative battery cable to the vehicle, if equipped without a battery current sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9510 4. Ensure that the engine harness terminal (3) is position behind the negative battery terminal (2). 5. Position the negative battery cable terminal (2) to the cylinder head. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the negative battery cable stud (1) to the front of the right cylinder head and tighten to 25 Nm (18 lb ft). 7. Install the negative battery cable clip (1) to the right wheelhouse liner. 8. Raise the vehicle. 9. Install the negative battery cable clip (2) to the chassis harness. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9511 10. Route the negative battery cable terminal (3) through the opening between the radiator support and frame. 11. Ensure that the negative battery cable is positioned behind the forward lamp harness. 12. Install the forward lamp wiring harness terminal (2) to the frame. Ensure that the anti-rotation tab is inserted into the hole in the frame. 13. Install the forward lamp wiring harness ground bolt (1) and tighten to 25 Nm (18 lb ft). 14. Lower the vehicle. 15. Install the battery current sensor (3) clip to the battery tray, if equipped with a battery current sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9512 16. Connect the engine harness electrical connector (1) to the battery current sensor. 17. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair). 18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: )Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: )Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: ). Auxiliary Battery Negative Cable REPLACEMENT Auxiliary Battery Negative Cable Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: )Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: )Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: ). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9513 2. Remove the auxiliary battery negative cable ground terminal bolt from the left cylinder head. 3. Remove the auxiliary battery negative cable from the vehicle. Installation Procedure 1. Install the auxiliary battery negative cable to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9514 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Position the auxiliary battery negative cable ground terminal to the left cylinder head and install the bolt and tighten to 25 Nm (18 lb ft). 3. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: )Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: )Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: ). Engine Ground Strap REPLACEMENT Engine Ground Strap Replacement (V8) Removal Procedure 1. Remove the engine wiring harness ground bolt. 2. Reposition the engine wiring harness ground and ground strap. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9515 3. Remove the ground strap nut from the stud at the front of dash. 4. Remove the ground strap from the stud. Installation Procedure 1. Install the ground strap to the stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ground strap nut to the stud at the front of dash and tighten to 9 Nm (80 lb in). 3. Position the ground strap and engine wiring harness ground. 4. Install the engine wiring harness ground bolt tighten to 16 Nm (12 lb ft). Battery Negative Cable Disconnection and CONNECTION Battery Negative Cable Disconnection and Connection Disconnect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). Note: Do NOT disconnect the negative battery cable from the battery until a period of at least 1 minute after performing the following: Turning the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. These steps are necessary to allow the brake system pressure relief procedure to occur. Failure to follow these steps may result in warning lamps and/or DTCs being set pertaining to interruption of the pressure relief procedure. Other vehicle systems may also be affected by not allowing a 1 minute duration for power-down. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9516 1. Turn off all lamps and accessories. 2. Turn the ignition OFF without pausing at ACCESSORY, and remove the ignition key. 3. Wait for at least 1 minute before disconnecting the negative battery cable from the battery, to allow for proper power-down procedures of certain vehicle systems. 4. Reposition the negative battery cable insulating cover (5) from the negative battery terminal. 5. Rotate the lever lock (4) counterclockwise in order to disconnect the negative battery cable from the battery. Connect Procedure Note: Clean any existing corrosion from the battery terminal and the battery cable. 1. Install the negative battery cable (6) to the battery. 2. Rotate the lever lock (4) clockwise until an audible click is heard in order to connect the negative battery cable to the battery. 3. Position the negative battery cable insulating cover (5) over the negative terminal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) Positive: Service and Repair Battery Positive Cable Replacement (Diesel) Battery Positive Cable Replacement (Gas) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Negative/Service and Repair). 2. Remove the underhood fuse block cover (1). 3. Lift the fuse block retainers (2) from the locked position and rotate the retainers to the open position. 4. Reposition the fuse block and remove the battery positive connector (3) from the underhood fuse block base. 5. Remove the battery positive cable retainers (1) from the studs on the plenum front panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9521 6. Remove the cover to the 175 amp mega fuse block. 7. Remove the battery positive cable nut (1) from the 175 amp mega fuse block. 8. Remove the positive battery cable from the vehicle. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the battery positive cable to the 175 amp mega fuse block with nut (1) and tighten to 10 Nm (88 lb in) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9522 2. Install the battery positive cable retainers (1) to the upper plenum.Install the battery positive cable clip nuts (1) to the studs on the upper plenum. 3. Install the battery positive cable connector (3) to the underhood fuse block. 4. Ensure that the underhood fuse block retainers (2) are in the open position. 5. Position and engage the junction block to the 4 bracket pivots, push the retainers (2) down into the locked position. 6. Install the underhood fuse block cover. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9523 Positive: Service and Repair Auxiliary Battery Positive Cable Replacement Auxiliary Battery Positive Cable Replacement Removal Procedure 1. Disconnect the negative battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Negative/Service and Repair) 2. If equipped with dual generators,remove the mega fuse nut (1) on top of the auxiliary battery. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9524 3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Negative/Service and Repair). 4. Disconnect the generator battery jumper cable. Refer to Generator Battery Jumper Cable Replacement (See: Service and Repair/Generator Battery Jumper Cable Replacement) 5. Loosen the auxiliary battery positive clamp nut (1) and remove the clamp from the battery post. 6. Remove the cable retainers (2) along the top of the fan shroud. 7. Remove the auxiliary battery positive harness clips (1) from the condensor hose and the transmission cooler hose. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9525 8. Remove the mega fuse block nut (1) and the auxiliary battery positive cable terminal (2), from the mega fuse block. Installation Procedure 1. If equipped with dual generators,connect the generator jumper cable (3) to the mega fuse holder with the nut (1) and tighten to 9 Nm (80 lb in) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9526 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the auxiliary battery positive clamp to the battery post and tighten clamp nut (1) to 9 Nm (80 lb in) 3. Install the auxiliary battery positive cable retainers (2) along the cooling fan shroud. 4. Install the auxiliary battery positive cable clips (1) to the condensor hose and the transmission cooler hose. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9527 5. Install the auxiliary battery positive cable terminal (2) to the mega fuse block and tighten the nut (1) to 9 Nm (80 lb in) 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9528 Positive: Service and Repair Auxiliary Battery Positive Cable Replacement - Battery to Battery Relay Auxiliary Battery Positive Cable Replacement - Battery to Battery Relay Removal Procedure 1. Disconnect the auxiliary battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Negative/Service and Repair). 2. Remove the underhood junction block cover. 3. Open the auxiliary battery positive cable post cover. 4. Loosen the auxiliary battery positive cable nut (2). 5. Remove the auxiliary battery positive cable from the battery positive post. 6. Remove the auxiliary battery positive cable nut (1) from the underhood junction block stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9529 7. Remove the auxiliary battery positive cable terminal from the underhood junction block stud. 8. Reposition the auxiliary battery positive cable boot (5) at the auxiliary battery relay. 9. Remove the auxiliary battery positive cable nut (6) from the rely stud. 10. Remove the auxiliary battery positive cable terminal from the relay stud. 11. Remove the auxiliary battery positive cable clips (4) from the engine wiring harness and remove the cable from the vehicle. Installation Procedure 1. Install the auxiliary battery positive cable to the vehicle. 2. Install the auxiliary battery positive cable terminal to the relay stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the auxiliary battery positive cable nut (6) to the rely stud and tighten to 7.5 Nm (66 lb in). 4. Position the auxiliary battery positive cable boot (5) at the auxiliary battery relay. 5. Install the auxiliary battery positive cable to the battery positive post. 6. Tighten the auxiliary battery positive cable nut (2) and tighten to 7.5 Nm (66 lb in). 7. Install the auxiliary battery positive cable terminal to the underhood junction block stud. 8. Install the auxiliary battery positive cable nut (1) to the underhood junction block stud and tighten to 5 Nm (44 lb in). 9. Install the auxiliary battery positive cable clips (4) to the engine wiring harness. 10. Close the auxiliary battery positive cable post cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9530 11. Install the underhood junction block cover. 12. Connect the auxiliary battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Negative/Service and Repair )Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9531 Positive: Service and Repair Battery Positive Cable Replacement (12V Battery to Auxiliary BEC) Battery Positive Cable Replacement (12V Battery to Auxiliary BEC) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Negative/Service and Repair). 2. Reposition the positive battery cable insulating cover (2) from over the positive terminal. 3. Rotate the lever lock (1) counterclockwise in order to disconnect the positive battery cable. 4. Remove the positive battery cable terminal (3) from the battery. 5. Remove the auxiliary bussed electrical center (BEC) cover (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9532 6. Remove the underhood junction block cover. 7. Lift the junction block retainers from the locked position (3) and rotate the retainers to the open position (1). 8. Remove the junction block. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9533 9. Remove the positive battery cable nut (1) from the mega fuse stud. 10. Remove the positive battery cable nut (3) from the auxiliary BEC stud. 11. Disconnect the positive battery cable connector (2) from the underhood BEC. 12. Remove the positive battery cable assembly (1) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9534 1. Install the positive battery cable assembly (1) to the vehicle. 2. Install the positive battery cable leads to the mega fuse and auxiliary BEC studs. 3. Connect the positive battery cable connector (2) to the underhood BEC. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the positive battery cable nut (3) to the auxiliary BEC stud and tighten to 9 Nm (80 lb in). 5. Install the positive battery cable nut (1) to the mega fuse stud and tighten to 9 Nm (80 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9535 6. Ensure that the junction block retainers are in the open position (1). 7. Position and align the junction block to the 4 bracket pivots (2), once the pivots are engaged, push the retainers down into the locked position (3). 8. Install the underhood junction block cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9536 9. Install the auxiliary BEC cover (1). 10. Install the positive battery cable terminal (3) to the battery. 11. Rotate the lever lock (1) clockwise until an audible click is heard in order to connect the positive battery cable. 12. Position the positive battery cable insulating cover (2) over the positive terminal. 13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9537 Positive: Service and Repair Battery Positive Cable Replacement (Control Module to Auxiliary BEC) Battery Positive Cable Replacement (Control Module to Auxiliary BEC) Removal Procedure 1. Disable the high voltage system. Refer to High Voltage Disabling (). 2. Remove the auxiliary bussed electrical center (BEC) cover (1). 3. Remove the positive battery cable nut (1) from the mega fuse stud. 4. Remove the positive battery cable lead (5) from the mega fuse stud. 5. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 6. Remove the positive battery cable clips (2, 3, and 4) from the frame crossmember. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9538 7. Working through the wheel opening, remove the positive battery cable clip (2) from the brake pipe. 8. Working through the wheel opening, remove the positive battery cable clip (3) from the air cleaner adapter bracket 9. Lower the vehicle. 10. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 11. Remove the positive battery cable clip (4) from the air cleaner support bracket. 12. Remove the positive battery cable clip (5) from the fender inner panel. 13. Disconnect the positive battery cable electrical connector (1) from the drive motor generator control module. 14. Remove the positive battery cable (1) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9539 1. Install the positive battery cable (1) to the vehicle. 2. Connect the positive battery cable electrical connector (1) to the drive motor generator control module. 3. Install the positive battery cable clip (5) to the fender inner panel. 4. Install the positive battery cable clip (4) to the air cleaner support bracket. 5. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 6. Raise and suitably support the vehicle enough to work through the wheel opening. 7. Working through the wheel opening, install the positive battery cable clip (3) to air cleaner adapter bracket 8. Working through the wheel opening, install the positive battery cable clip (2) to the brake pipe. 9. Fully raise the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9540 10. Install the positive battery cable clips (2, 3, and 4) to the frame crossmember. 11. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 12. Lower the vehicle. 13. Install the positive battery cable lead (5) to the mega fuse stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 14. Install the positive battery cable nut (1) to the mega fuse stud and tighten to 9 Nm (80 lb in). 15. Install the auxiliary BEC cover (1). 16. Enable the high voltage system. Refer to High Voltage Enabling (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information > Diagrams > Page 9544 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Battery Cable/Negative/Service and Repair). 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information > Diagrams > Page 9545 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Auxiliary Battery Tray Replacement Battery Tray: Service and Repair Auxiliary Battery Tray Replacement Auxiliary Battery Tray Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Auxiliary Battery Tray Replacement > Page 9550 Battery Tray: Service and Repair Battery Tray Replacement Battery Tray Replacement Removal Procedure 1. Remove the battery. Refer to Battery Replacement (See: Service and Repair/Removal and Replacement/Battery Replacement). 2. Remove the battery tray front support bolts. 3. Remove the battery tray front support. 4. Remove the nut securing the battery tray to the front fender inner panel. 5. Remove the 3 nuts securing the battery tray to the battery tray bracket. 6. Remove the battery tray from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Auxiliary Battery Tray Replacement > Page 9551 1. Install the battery tray to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 nuts securing the battery tray to the battery tray bracket and tighten to 20 Nm (15 lb ft). 3. Install the nut securing the battery tray to the front fender inner panel and tighten to 9 Nm (80 lb in). 4. Install the battery tray front support. 5. Install the battery tray front support bolts and tighten to 20 Nm (15 lb ft). 6. Install the battery. Refer to Battery Replacement (See: Service and Repair/Removal and Replacement/Battery Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications Alternator: Specifications Generator Usage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 9556 Alternator: Diagrams Component Connector End Views Generator X1 (Gas) Generator X2 (LU3) Generator X2 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement (V8) Alternator: Service and Repair Generator Bracket Replacement (V8) Generator Bracket Replacement (V8) Removal Procedure 1. Remove the generator. Refer to Generator Replacement (V6) (See: )Generator Replacement (V8) (See: )Generator Replacement (6.6L) (See: ). 2. Remove the power steering pump. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (4.3L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (6.6L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair). 3. Remove the engine wiring harness clip bolt (3) are reposition the clip (1) away from the generator bracket. 4. Remove the generator bracket bolts. 5. Remove the generator bracket. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement (V8) > Page 9559 1. Position the generator bracket to the engine. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the generator bracket bolts. Tighten the bolts to 50 Nm (37 lb ft). 3. Position the engine wiring harness clip (1) to the generator bracket and install the engine harness clip bolt (3). Tighten the bolt to 9 Nm (80 lb in). 4. Install the power steering pump. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (4.3L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (6.6L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair). 5. Install the generator. Refer to Generator Replacement (V6) (See: )Generator Replacement (V8) (See: )Generator Replacement (6.6L) (See: ). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement (V8) > Page 9560 Alternator: Service and Repair Auxiliary Generator Bracket Replacement (Diesel) Auxiliary Generator Bracket Replacement (Diesel) Removal Procedure 1. Remove the auxiliary generator. Refer to Auxiliary Generator Replacement (6.6L) (). 2. Remove the auxiliary generator bracket bolt (2). 3. Remove the auxiliary generator bracket (1). Installation Procedure 1. Position the auxiliary generator bracket (2) to the air conditioning (A/C) bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement (V8) > Page 9561 2. Install the auxiliary generator bracket bolt (1). Tighten the bolt to 50 Nm (37 lb ft). 3. Install the auxiliary generator. Refer to Auxiliary Generator Replacement (6.6L) (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement (V8) > Page 9562 Alternator: Service and Repair Generator Replacement (V8) Generator Replacement (V8) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). 2. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 3. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory). 4. Disconnect the engine harness electrical connector (3) from the generator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement (V8) > Page 9563 5. Reposition the generator battery jumper cable boot (3). 6. Remove the generator battery jumper cable nut (2) from the generator. 7. Remove the generator battery jumper cable terminal (1) from the generator stud. 8. Remove the generator bolts. 9. Remove the generator. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement (V8) > Page 9564 1. Install the generator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the generator bolts. Tighten the bolts to 55 Nm (41 lb ft). 3. Install the generator battery jumper cable terminal (1) to the generator stud. 4. Install the generator battery jumper cable nut (2) to the generator. Tighten the nut to 9 Nm (80 lb in). 5. Position the generator battery jumper cable boot (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement (V8) > Page 9565 6. Connect the engine harness electrical connector (3) to the generator. 7. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory). 8. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 9572 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 9573 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note: The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 9574 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 9579 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 9580 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 9581 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter Diagnostic Tip INFORMATION Bulletin No.: 09-08-52-004A Date: January 08, 2010 Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter When Transmitter Battery is Weak or Dead Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR, Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories). Follow these procedures if a customer comments that their GM Accessory 2-way transmitter stopped communicating with the vehicle. About GM Accessory 2-Way Remote Start The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a 2-way advanced remote start system, but often the 2-way transmitter may only be coded to one vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter will enter second vehicle mode and will not control the original vehicle until a subsequent double press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of the 2-way transmitter should be thought of as an individual transmitter with its own unique code. Test the Transmitter Battery Note This test should be performed prior to releasing the vehicle or transmitter to the customer. All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or replacement of a transmitter battery using the following procedure. 1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of the unlock button, observe the battery gauge located in the upper right corner of the LCD display. The gauge should read full (three bars inside the battery icon). If after having a new battery installed, the battery goes dead within five months, the transmitter could have high sleep current, causing the battery to go dead. Replace the transmitter. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. Determine if Transmitter is in Second Vehicle Mode 1. Press and release any of the face buttons on the 2-way transmitter and observe the display on power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be displayed on the left side of the transmitter display. Is the 2-way transmitter in second vehicle mode? If Yes, the 2-way transmitter is working properly. - Press and release the left side button twice within one second. The 2-way transmitter should exit second vehicle mode. - Press and release the lock button. Press and release the unlock button. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 9587 - Confirm that the vehicle responds with the appropriate lock and unlock function. - If Yes , the 2-way transmitter was in mode B. - Press and release the left side button twice within one second. The 2-way transmitter should enter second vehicle mode. - Use the "next available slot" method in the scan tool to program the 2-way transmitter to the 2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI. - Both vehicle modes of the 2-way transmitter should now be coded to the vehicle. If No: The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal diagnostic procedures. Parts Information For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts Catalog or Corporate Bulletin Number 09-00-89-025A. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 9588 Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote Start INFORMATION Bulletin No.: 09-00-89-025A Date: October 26, 2009 Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT 2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent 2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA, OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY Attention: This bulletin does not apply to GMODC dealers. Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin Number 09-00-89-025 (Section 00 - General Information). This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems. Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 9589 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 9590 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 9591 Parts Information Service parts common to all 2-Way Advanced Remote Start Systems Transmitter Battery 12493150 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams Starter Motor: Diagrams Component Connector End Views Starter Motor X1 (5X7) Starter Motor X1 (LU3 without 9L4) Starter Motor X1 (6A6) Starter Motor X1 (9L4 or Gas except LU3) Starter Motor X2 (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 9595 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 9596 Starter Motor: Service and Repair Starter Replacement (V8) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. For 2500 series vehicles, remove the front 2 oil pan skid plate bolts, loosen the rear 2 bolts and remove the skid plate, if equipped. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 9597 4. Remove the transmission cover bolt. 5. Remove the starter bolts. 6. Disconnect the engine wiring harness electrical connector (4) from the oil level sensor. Caution: Avoid cable and wiring damage. DO NOT suspend the starter by the cables or wires attached to the solenoid terminals. Use a rope or mechanics wire to suspend the starter. 7. Slide the starter forward until the starter clears the transmission and properly support the starter. 8. Lower the vehicle half way. 9. Remove the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 10. Remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 9598 Replacement - Right Side). 11. Remove the engine wiring harness lead nut (1). 12. Remove the engine wiring harness lead terminal (2) from the starter. 13. Remove the starter solenoid cable clip bolt (2) from the frame. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 9599 14. Remove the starter solenoid cable nut (1). 15. Remove the starter solenoid cable (2) from the starter. 16. Remove the starter out through the wheel well opening. 17. If replacing the starter, unsnap the transmission cover from the starter. Note: If the starter shield is damaged, replace the starter shield. 18. If replacing the starter, remove the starter heat shield. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 9600 1. If the starter was replaced, install the starter heat shield. 2. If the starter was replaced, snap the transmission cover onto the starter. 3. Install the starter in through the wheel well opening. 4. Install the starter solenoid cable to the starter. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the starter solenoid cable nut (1). Tighten the nut to 9 Nm (80 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 9601 6. Position the starter solenoid cable clip to the frame and install the starter solenoid cable clip bolt (2). Tighten the bolt to 10 Nm (89 lb in). 7. Install the engine wiring harness lead terminal (2) to the starter. 8. Install the engine wiring harness lead nut (1). Tighten the nut to 3.4 Nm (30 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 9602 9. Position the starter into place. 10. Install the starter bolts. Tighten the bolts to 50 Nm (37 lb ft). 11. Install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 12. Install the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 13. Raise and support the vehicle. 14. Connect the engine wiring harness electrical connector (4) to the oil level sensor. 15. Install the transmission cover bolt. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 9603 Tighten the bolt to 9 Nm (80 lb in). 16. For 2500 series vehicles, install the oil pan skid plate and tighten the rear 2 bolts and install and tighten the front 2 bolts, if equipped. Tighten the bolts to 28 Nm (21 lb ft). 17. Lower the vehicle. 18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 9607 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 9608 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 9609 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 9610 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 9611 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 9612 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 9613 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Service and Repair Starter Solenoid: Service and Repair Starter Solenoid Switch Replacement (Diesel) Removal Procedure 1. Remove the starter motor. Refer to Starter Replacement (V8) (See: Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starter Motor/Service and Repair). 2. Reposition the M-terminal stud weather cover (1). 3. Clean the epoxy coating (2) from the M-terminal stud. 4. Loosen the M-terminal stud nut. 5. Remove the cable from the M-terminal stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Service and Repair > Page 9617 6. Remove the solenoid bolts (1). 7. Separate the solenoid from the housing and unhook the solenoid plunger (2) from the drive gear lever (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Service and Repair > Page 9618 8. Note that the spring (3) is positioned against the drive gear lever (1) and the drive gear lever is placed inside the solenoid plunger loop (2). 9. Remove the solenoid housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Service and Repair > Page 9619 10. If necessary, remove the solenoid plunger and spring. Installation Procedure 1. If necessary, install the solenoid plunger and spring. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Service and Repair > Page 9620 2. Using Three Bond silicone 1207B, GM P/N 97720043, seal the starter solenoid attachment area. Note: Ensure that the drive gear lever (1) is properly installed into the solenoid plunger (2) loop. Improper installation of the drive gear lever will cause an abnormal or no operation condition of the starter. 3. Install the solenoid, making sure to insert the drive gear lever (1) into the solenoid plunger (2) loop, perform the following: 1. Pull the gear lever (1) out away from the starter housing and pull the plunger (2) out away from the solenoid. 2. Tip the solenoid and insert the lever into the loop, push the solenoid against the housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Service and Repair > Page 9621 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the solenoid bolts (1). Tighten the bolts to 10 Nm (89 lb in). 5. Wipe the excess silicone pressed out during the solenoid installation from around the base of the solenoid to make a weather proof seal. 6. Install the cable to the M-terminal stud between the washers and terminal nut. 7. Tighten the M-terminal stud nut. Tighten the nut to 8 Nm (71 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Service and Repair > Page 9622 8. Using Three Bond silicone 1207B, GM P/N 97720043, seal the M-terminal stud connection (2). 9. Reposition the M-terminal stud weather cover (1). 10. Bench test the starter in a free-run condition prior to installation. 11. Install the starter motor. Refer to Starter Replacement (V8) (See: Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starter Motor/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9628 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9629 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9630 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9631 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9632 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9633 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9634 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9635 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9636 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9637 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9638 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9639 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9640 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9641 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9642 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9643 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9644 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9645 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9646 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9647 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9648 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9649 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9650 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9651 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9652 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9653 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9654 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9655 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9656 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9657 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9658 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9659 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9660 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9661 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9662 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9663 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9664 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9665 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9666 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9667 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9668 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9669 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9670 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9671 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9672 Auxiliary Power Outlet: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9673 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9674 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9675 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9676 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9677 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9678 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9679 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9680 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9681 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9682 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9683 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9684 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9685 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9686 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9687 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9688 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9689 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9690 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9691 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9692 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9693 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9694 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9695 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9696 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9697 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9698 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9699 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9700 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9701 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9702 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9703 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9704 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9705 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9706 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9707 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9708 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9709 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9710 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9711 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9712 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9713 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9714 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9715 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9716 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9717 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9718 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9719 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9720 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9721 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9722 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9723 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9724 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9725 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9726 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9727 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9728 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9729 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9730 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9731 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9732 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9733 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9734 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9735 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9736 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9737 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9738 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9739 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9740 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9741 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9742 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9743 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9744 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9745 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9746 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9747 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9748 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9749 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9750 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9751 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9752 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9753 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9754 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9755 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9756 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9757 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9758 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9759 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9760 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9761 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9762 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9763 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9764 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9765 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9766 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9767 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9768 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9769 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9770 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9771 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9772 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9773 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9774 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9775 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9776 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9777 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9778 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9779 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9780 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9781 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9782 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9783 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9784 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9785 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9786 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9787 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9788 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9789 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9790 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9791 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9792 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9793 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9794 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9795 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9796 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9797 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9798 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9799 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9800 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9801 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9802 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9803 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9804 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9805 Auxiliary Power Outlet: Connector Views Component Connector End Views Accessory Power Outlet - Center Console (D07) Accessory Power Outlet - Center Console Compartment (D07) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9806 Accessory Power Outlet - Center Seat (AZ3) Accessory Power Outlet - I/P 1 Accessory Power Outlet - I/P 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9807 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9808 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Power Outlet Schematics Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 9809 Auxiliary Power Outlet: Description and Operation Power Outlets Description and Operation 12 Volt Power Outlet Receptacle Description and Operation The accessory power receptacles are supplied battery voltage at all times. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets Auxiliary Power Outlet: Testing and Inspection Symptoms - Power Outlets Symptoms - Power Outlets Visual/Physical Inspection * Inspect for aftermarket devices which can affect the operation of the power outlets. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories) * Inspect the accessible system components or the visible system components for obvious damage or for obvious conditions which can cause the symptom. Intermittent Electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) Symptom List Refer to Power Outlet Receptacle Malfunction (See: Power Outlet Receptacle Inoperative (120 VAC)) in order to diagnose the system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets > Page 9812 Auxiliary Power Outlet: Testing and Inspection Power Outlet Receptacle Inoperative (120 VAC) Power Outlet Receptacle Malfunction Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The accessory power receptacles are supplied B+ all the time. Reference Information Schematic Reference Cigar Lighter/Power Outlet Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Power Outlets Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the appropriate X80 accessory power receptacle. 2. Test for less than 5 ohm between the ground circuit terminal C and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Verify that a test lamp illuminate between the B+ circuit terminal A and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. 4. If all circuits test normal, test or replace the X80 accessory power receptacle. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets > Page 9813 Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement (See: Service and Repair) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Page 9814 Auxiliary Power Outlet: Service and Repair Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Tools Required J 42059 Cigar Lighter Socket Remover Removal Procedure 1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle: 1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the front of the receptacle. The J 42059 pushes the plastic latches from these tab windows and the receptacle can be pulled straight out. 2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit straight into the receptacle. Angle the J 42059 slightly for insertion into the receptacle. 3. Insert the other side of the "T" into the opposite tab window. You must move the J 42059 handle toward horizontal to engage the other tab window. 4. Use the J 42059 to pull the receptacle straight out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Page 9815 3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. Installation Procedure 1. Route the connector through the retainer. Align the accessory power receptacle retainer to the slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer. Install the accessory power receptacle by pressing into place until fully seated. 5. Install the accessory power receptacle fuse. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Page 9816 Auxiliary Power Outlet: Tools and Equipment Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 9825 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 9831 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual Fuse: Locations Center Instrument Panel Fuse Block - Owners Manual CENTER INSTRUMENT PANEL FUSE BLOCK The center instrument panel fuse block is located underneath the instrument panel, to the left of the steering column. TOP VIEW HARNESS CONNECTOR - USAGE BODY 2 ............................................................................................................................................... ................................... Body Harness Connector 2 BODY 1 ............................................................... ................................................................................................................... Body Harness Connector 1 BODY 3 ............................................................................................................................................ ...................................... Body Harness Connector 3 HEADLINER 3 .................................................. .............................................................................................................. Headliner Harness Connector 3 HEADLINER 2 ................................................................................................................ ................................................ Headliner Harness Connector 2 HEADLINER 1 ................................. ............................................................................................................................... Headliner Harness Connector 1 SEO/UPFITTER .......................................................................................................................... Special Equipment Option Upfitter Harness Connector CIRCUIT BREAKER - USAGE CB1 ......................................................................................................................................................... Passenger Side Power Window Circuit Breaker CB2 ......................................................................... .......................................................................................................... Passenger Seat Circuit Breaker CB3 ...................................................................................................................................................... .................................. Driver Seat Circuit Breaker CB4 ....................................................................... .......................................................................................................................... Rear Sliding Window Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 9836 Fuse: Locations Instrument Panel Fuse Block - Owners Manual INSTRUMENT PANEL FUSE BLOCK The instrument panel fuse block access door is located on the driver side edge of the instrument panel. Pull off the cover to access the fuse block. The vehicle may not use all of the fuses shown. FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. .............................................................. Rear Seats Fuse 2 ................................................................ .................................................................................................................. Rear Accessory Power Outlet Fuse 3 ....................................................................................................................................... ................................... Steering Wheel Controls Backlight Fuse 4 ...................................................... .......................................................................................................................................... Driver Door Module Fuse 5 ..................................................................................................................................... ............................... Dome Lamps, Driver Side Turn Signal Fuse 6 .................................................... ...................................................................................................................... Driver Side Turn Signal, Stoplamp Fuse 7 ................................................................................................................................. .............................................. Instrument Panel Back Lighting Fuse 8 ................................................ .................................................................................................................... Passenger Side Turn Signal, Stoplamp Fuse 9 ..................................................................................................................... ............................................. Passenger Door Module, Driver Unlock Fuse 10 .................................. ................................................................................................................................. Power Door Lock 2 (Unlock Feature) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 9837 Fuse 11 ................................................................................................................................................ ....................... Power Door Lock 2 (Lock Feature) Fuse 12 ......................................................................................................................................................... Stoplamps, Center-High Mounted Stoplamp Fuse 13 ......................................................................... .................................................................................................................. Rear Climate Controls Fuse 14 ................................................................................................................................................ ......................................................... Power Mirror Fuse 15 ................................................................ ............................................................................................................... Body Control Module (BCM) Fuse 16 ................................................................................................................................................ ....................................... Accessory Power Outlets Fuse 17 .............................................................. ......................................................................................................................................... Interior Lamps Fuse 18 .................................................................................................................................... ............................... Power Door Lock 1 (Unlock Feature) Fuse 19 .................................................... .................................................................................................................................... Rear Seat Entertainment Fuse 20 ..................................................................................................................................................... Ultrasonic Rear Parking Assist, Power Liftgate Fuse 21 ..................................................................... .................................................................................................. Power Door Lock 1 (Lock Feature) Fuse 22 ................................................................................................................................................ ........................... Driver Information Center (DIC) Fuse 23 ................................................................. ............................................................................................................................................ Rear Wiper Fuse 24 ..................................................................................................................................... ..................................................................... Cooled Seats Fuse 25 .............................................................................................................................................. Driver Seat Module, Remote Keyless Entry System Fuse 26 ........................................................................................................................................................... Driver Power Door Lock (Unlock Feature) CIRCUIT BREAKER ............................................................................................................................ ................................................................ USAGE LT DR .......................................................................................................................................................... Driver Side Power Window Circuit Breaker HARNESS CONNECTOR ................................................................................................................... ................................................................. USAGE LT DR .................................................................................................................................................. .......................... Driver Door Harness Connection BODY .................................................................. ................................................................................................................................ Harness Connector BODY ................................................................................................................................. ................................................................. Harness Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 9838 Fuse: Locations Underhood Fuse Block - Owners Manual UNDERHOOD FUSE BLOCK The underhood fuse block is located in the engine compartment, on the driver side of the vehicle. Lift the cover to access the fuse block. Notice: Spilling liquid on any electrical components on the vehicle may damage it. Always keep the covers on any electrical component. To remove fuses, hold the end of the fuse between your thumb and index finger and pull straight out. FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. ............................... Right Trailer Stop/Turn Lamp Fuse 2 ......................................................................................................................... Electronic Suspension Control, Automatic Level Control Exhaust Fuse 3 ............................................................................... .................................................................................................... Left Trailer Stop/Turn Lamp Fuse 4 .............................................................................................................................................................. ......................................... Engine Controls Fuse 5 ............................................................................. .................................................................................. Engine Control Module, Throttle Control Fuse 6 ........................................................................................................................................................... ............................... Trailer Brake Controller Fuse 7 ........................................................................... ................................................................................................................................ Front Washer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 9839 Fuse 8 .................................................................................................................................................. ....................................................... Oxygen Sensor Fuse 9 ................................................................ ........................................................................................................................ Antilock Brakes System 2 Fuse 10 ................................................................................................................................ .......................................................... Trailer Back-up Lamps Fuse 11 ............................................... .......................................................................................................................... Driver Side Low-Beam Headlamp Fuse 12 ............................................................................................................ .............................................................. Engine Control Module (Battery) Fuse 13 ............................................................................................................................................................. Fuel Injectors, Ignition Coils (Right Side) Fuse 14 .............................................................................. .................................................................................. Transmission Control Module (Battery) Fuse 15 ......................................................................................................................................................... ................................ Vehicle Back-up Lamps Fuse 16 ........................................................................ ........................................................................................... Passenger Side Low-Beam Headlamp Fuse 17 ................................................................................................................................................ ................................ Air Conditioning Compressor Fuse 18 ................................................................ ..................................................................................................................................... Oxygen Sensors Fuse 19 ................................................................................................................................. .......................................... Transmission Controls (Ignition) Fuse 20 ................................................. ............................................................................................................................................................. Fuel Pump Fuse 21 ............................................................................................................................. .................................................... Fuel System Control Module Fuse 22 ............................................ .............................................................................................................................................................. ...... Not Used Fuse 23 ......................................................................................................................... ....................................................................................... Not Used Fuse 24 ........................................ ....................................................................................................................... Fuel Injectors, Ignition Coils (Left Side) Fuse 25 ..................................................................................................................... ........................................................................... Trailer Park Lamps Fuse 26 .................................... ..................................................................................................................................................... Driver Side Park Lamps Fuse 27 ......................................................................................................... .......................................................................... Passenger Side Park Lamps Fuse 28 ...................... .............................................................................................................................................................. ......................... Fog Lamps Fuse 29 ................................................................................................... .................................................................................................................... Horn Fuse 30 .................. ................................................................................................................................................. Passenger Side High-Beam Headlamp Fuse 31 ................................................................................. ........................................................................................... Daytime Running Lamps (DRL) Fuse 32 . .............................................................................................................................................................. ......... Driver Side High-Beam Headlamp Fuse 33 .............................................................................. ....................................................................................................... Daytime Running Lights 2 Fuse 34 ......................................................................................................................................................... ......................................................... Sunroof Fuse 35 ....................................................................................................................................................... Key Ignition System, Theft Deterrent System Fuse 36 ........................................................................ .......................................................................................................................... Windshield Wiper Fuse 37 ................................................................................................................................................ .......................... SEO B2 Upfitter Usage (Battery) Fuse 38 ................................................................ ..................................................................................................................... Electric Adjustable Pedals Fuse 39 .................................................................................................................................... ................................................. Climate Controls (Battery) Fuse 40 ................................................... .................................................................................................................................... Airbag System (Ignition) Fuse 41 ................................................................................................................................. .............................................................................. Amplifier Fuse 42 .................................................. ....................................................................................................................................................... Audio System Fuse 43 ........................................................................................................................ ....................................... Miscellaneous (Ignition), Cruise Control Fuse 44 ........................................ .............................................................................................................................................................. .......... Not Used Fuse 45 ..................................................................................................................... ................................................................... Airbag System (Battery) Fuse 46 .................................... .................................................................................................................................................... Instrument Panel Cluster Fuse 47 ....................................................................................................... .............................................................................................. Power Take-Off Fuse 48 ...................... ............................................................................................................................................... Auxiliary Climate Control (Ignition) Fuse 49 ........................................................................................................................................................... Center High-Mounted Stoplamp (CHMSL) Fuse 50 ............................................................................ ............................................................................................................................ Rear Defogger Fuse 51 ......................................................................................................................................................... .............................................. Heated Mirrors Fuse 52 ........................................................................ .................................................................................................. SEO B1 Upfitter Usage (Battery) Fuse 53 ............................................................................................................................................................. Cigarette Lighter, Auxiliary Power Outlet Fuse 54 ............................................................................... ................................................................................................................ SEO Upfitter Usage Fuse 55 ......................................................................................................................................................... ........................... Climate Controls (Ignition) Fuse 56 .................................................................................................................................... Engine Control Module, Secondary Fuel Pump (Ignition) J-CASE FUSES ................................................................................................................................... ................................................................... USAGE Fuse 57 ................................................................................................................................................ ........................................................ Cooling Fan 1 Fuse 58 ............................................................... ................................................................................................................................................. Not Used Fuse 59 ...................................................................................................................................... ................................ Heavy Duty Antilock Brake System Fuse 60 ...................................................... .................................................................................................................................................. Cooling Fan 2 Fuse 61 ........................................................................................................................ ............................................................... Antilock Brake System 1 Fuse 62 ........................................ .............................................................................................................................................................. .............. Starter Fuse 63 ..................................................................................................................... ..................................................................... Stud 2 (Trailer Brakes) Fuse 64 .................................... ......................................................................................................................................... Left Bussed Electrical Center 1 Fuse 65 ................................................................................................................. ............................................................................................... Not Used Fuse 66 ................................ ....................................................................................................................................... Heated Windshield Washer System Fuse 67 ................................................................................................... ...................................................................................................... Transfer Case Fuse 68 ........................................................................................................ Stud 1 (Trailer Connector Battery Power) (Optional - 40A Fuse Required) Fuse 69 .................................................. ........................................................................................................................... Mid-Bussed Electrical Center 1 Fuse 70 ................................................................................................................. ........................................................................ Climate Control Blower Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 9840 Fuse 71 ................................................................................................................................................ ................................................................ Not Used Fuse 72 ............................................................... .............................................................................................................. Left Bussed Electrical Center 2 RELAYS .............................................................................................................................................. .................................................................... USAGE FAN HI ................................................................................................................................................. ...................................... Cooling Fan High Speed FAN LO ................................................................ ....................................................................................................................... Cooling Fan Low Speed FAN CNTRL ............................................................................................................................. ........................................................ Cooling Fan Control HDLP LO/HID ............................................ .................................................................................................................................... Low-Beam Headlamp FOG LAMP ......................................................................................................................... ................................................................... Front Fog Lamps A/C CMPRSR ...................................... ............................................................................................................................... Air Conditioning Compressor STRTR ............................................................................................................................ ........................................................................................ Starter PWR/TRN ....................................... .............................................................................................................................................................. ... Powertrain FUEL PMP .................................................................................................................... ................................................................................... Fuel Pump PRK LAMP .................................... ............................................................................................................................................................ Parking Lamps REAR DEFOG ............................................................................................................ ............................................................................... Rear Defogger RUN/CRANK ............................... .......................................................................................................................................................... Switched Power Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood Fuse: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9843 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9844 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9845 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9846 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9847 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9848 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9849 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9850 Fuse Block - Underhood Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9851 Fuse Block - Underhood X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9852 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9853 Fuse Block - Underhood X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9854 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9855 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9856 Fuse Block - Underhood X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9857 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9858 Fuse Block - Underhood X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9859 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9860 Fuse Block - Underhood X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9861 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9862 Fuse Block - Underhood X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9863 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9864 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9865 Fuse: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9866 Fuse Block - I/P Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9867 Fuse Block - I/P Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9868 Fuse Block - I/P X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9869 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9870 Fuse Block - I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9871 Fuse Block - I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9872 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9873 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9874 Fuse: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9875 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9876 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9877 Fuse: Application and ID Fuse Holder Electrical Center Identification Views Fuse Block - Auxiliary, Fuse Holder (HP2) Fuse Block - Auxiliary, Fuse Holder (HP2) Fuse Holder X1 (Gas except 9L4) Fuse Holder X1 (Diesel or Gas with 9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9878 Fuse Holder X2 (Gas with TP2) Fuse Holder X2 (Diesel or Gas except LU3) Fuse Holder X2 (LU3) Fuse Holder X2 (Gas except LU3) Fuse Holder X2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9879 Fuse Holder X3 (9L4) Fuse Holder X3 (Diesel) Fuse Holder X4 (TP2) Fuse Holder X4 (Diesel) Fuse Holder X4 (Diesel with K76 or YF2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9880 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9881 Fuse: Application and ID Junction Block Electrical Center Identification Views Junction Block - Left I/P, Label Junction Block - Left I/P, Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9882 Junction Block - Left I/P, Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9883 Junction Block - Left I/P X1 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9884 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9885 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9886 Junction Block - Left I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9887 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9888 Junction Block - Left I/P X3 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9889 Junction Block - Left I/P X4 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9890 Junction Block - Left I/P X5 (SPO Alarm or SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9891 Junction Block - Left I/P X7 (JF4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9892 Junction Block - Left I/P X8 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9893 Junction Block - Left I/P X9 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9894 Junction Block - Left I/P X10 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9895 Junction Block - Left I/P X11 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9896 Junction Block - Left I/P X12 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9897 Junction Block - Left I/P X13 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9898 Junction Block - Left I/P X14 (5X7, 5Y0, 9L4, SPO DVD or SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9899 Junction Block - Right I/P, Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9900 Junction Block - Right I/P (Wire Entry) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9901 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9902 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9903 Junction Block - Right I/P X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9904 Junction Block - Right I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9905 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9906 Junction Block - Right I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9907 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9908 Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9909 Junction Block - Rear Lamps X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9910 Junction Block - Rear Lamps X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 9911 Junction Block - Rear Lamps X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9916 Fuse Block - I/P Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9917 Fuse Block - I/P Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9918 Fuse Block - I/P X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9919 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9920 Fuse Block - I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9921 Fuse Block - I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9922 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9923 Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9924 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9925 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9926 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9927 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9928 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9929 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9930 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9931 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9932 Fuse Block - Underhood Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9933 Fuse Block - Underhood X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9934 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9935 Fuse Block - Underhood X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9936 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9937 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9938 Fuse Block - Underhood X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9939 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9940 Fuse Block - Underhood X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9941 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9942 Fuse Block - Underhood X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9943 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9944 Fuse Block - Underhood X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9945 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9946 Fuse Block - Underhood X8 (JL1) Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9947 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9948 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9949 Fuse Block: Connector Locations Harness Routing Views Chassis Harness Routing (Except LY6/LMM/HP2) 1 - X300 2 - X408 (UD7) 3 - G401 4 - J423 (except LU3) 5 - J331 6 - Fuse Block - Underhood X3 7 - X115 8 - X102 (JL1) 9 - J338 (except LU3/LMG) 10 - J300 11 - G300 Chassis Harness Routing (LY6/LMM except 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9950 1 - X300 2 - X408 (UD7) 3 - Trailer Connector (UY7) 4 - J411 (JL1) 5 - G401 6 - J331 7 - Fuse Block - Underhood X3 8 - X115 9 - X102 (JL1) 10 - J300 11 - G300 Chassis Harness - Front Engine Compartment (31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9951 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Driver Door Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9952 1 - Door Frame 2 - Fuse Block - I/P X4 3 - J502 (YE9 without AN3) 4 - X500 (YE9 without AN3/DL3) 5 - X502 (ASF without YE9 or with AN3) Engine Harness Routing - Left Side (4.3L) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9953 1 - Throttle Body 2 - G107 3 - Transmission 4 - X300 5 - X109 6 - X110 (NQG/NQH) 7 - Fuse Block - Underhood X2 Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9954 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9955 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) I/P Harness Routing - Engine Compartment (Except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 9956 1 - G110 (XA7) 2 - J113 (NQH) 3 - Fuse Block - Underhood X5 4 - Fuse Block - Underhood X4 5 Left Front Fender 6 - X103 7 - X109 8 - X115 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9959 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9960 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9961 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9962 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9963 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9964 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9965 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9966 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9967 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9968 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9969 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9970 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9971 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9972 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9973 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9974 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9975 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9976 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9977 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9978 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9979 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9980 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9981 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9982 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9983 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9984 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9985 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9986 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9987 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9988 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9989 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9990 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9991 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9992 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9993 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9994 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9995 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9996 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9997 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9998 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 9999 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10000 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10001 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10002 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10003 Fuse Block: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10004 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10005 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10006 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10007 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10008 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10009 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10010 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10011 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10012 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10013 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10014 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10015 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10016 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10017 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10018 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10019 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10020 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10021 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10022 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10023 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10024 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10025 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10026 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10027 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10028 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10029 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10030 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10031 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10032 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10033 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10034 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10035 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10036 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10037 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10038 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10039 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10040 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10041 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10042 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10043 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10044 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10045 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10046 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10047 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10048 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10049 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10050 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10051 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10052 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10053 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10054 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10055 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10056 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10057 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10058 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10059 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10060 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10061 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10062 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10063 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10064 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10065 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10066 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10067 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10068 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10069 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10070 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10071 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10072 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10073 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10074 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10075 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10076 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10077 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10078 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10079 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10080 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10081 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10082 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10083 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10084 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10085 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10086 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10087 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10088 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10089 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10090 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10091 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10092 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10093 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10094 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10095 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10096 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10097 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10098 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10099 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10100 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10101 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10102 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10103 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10104 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10105 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10106 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10107 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10108 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10109 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10110 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10111 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10112 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10113 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10114 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10115 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10116 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10117 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10118 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10119 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10120 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10121 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10122 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10123 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10124 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10125 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10126 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10127 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10128 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10129 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10130 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10131 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10132 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10133 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10134 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10135 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10136 Fuse Block: Connector Views Electrical Center Identification Views Junction Block - Left I/P, Label Junction Block - Left I/P, Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10137 Junction Block - Left I/P, Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10138 Junction Block - Left I/P X1 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10139 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10140 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10141 Junction Block - Left I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10142 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10143 Junction Block - Left I/P X3 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10144 Junction Block - Left I/P X4 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10145 Junction Block - Left I/P X5 (SPO Alarm or SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10146 Junction Block - Left I/P X7 (JF4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10147 Junction Block - Left I/P X8 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10148 Junction Block - Left I/P X9 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10149 Junction Block - Left I/P X10 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10150 Junction Block - Left I/P X11 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10151 Junction Block - Left I/P X12 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10152 Junction Block - Left I/P X13 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10153 Junction Block - Left I/P X14 (5X7, 5Y0, 9L4, SPO DVD or SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10154 Junction Block - Right I/P, Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10155 Junction Block - Right I/P (Wire Entry) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10156 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10157 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10158 Junction Block - Right I/P X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10159 Junction Block - Right I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10160 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10161 Junction Block - Right I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10162 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10163 Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10164 Junction Block - Rear Lamps X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10165 Junction Block - Rear Lamps X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10166 Junction Block - Rear Lamps X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures Fuse Block: Procedures Ground Repair Electrical Grounds Proper electrical system function relies on secure, positive, corrosion-free ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacements. In general, electrical ground connections are accomplished using one, or a combination of, three attachment methods: * Welded M6 stud and nut * Welded M6 nut and bolt * Welded M8 nut and bolt Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. Determine which attachment method is used, and carry out the appropriate repair. M6 Weld Stud Replacement 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 5. Select a replacement conductive M6 rivet stud. Refer to GM parts catalog for the correct part number and application. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new rivet stud. 16. Select a new, conductive M6 nut. Refer to GM parts catalog for the correct part number and application. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 17. Install the M6 nut and tighten to 8 Nm (71 lb in). 18. Check for proper system operation. M6 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a new, conductive self-threading M7 bolt may be used to secure the ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive, self-threading M7 bolt Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10169 threads. 5. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 6. Install the electrical ground terminal to the new, conductive M7 bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the M7 bolt and tighten to 9 Nm (80 lb in). 8. Check for proper system operation. M6 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a conductive M6 bolt and a conductive M6 nut may be used to secure the electrical ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 ) clearance behind the panel surface and 20 mm (0.79 ) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M6 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M6 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). Note: The repair area must be properly refinished to maintain positive electrical grounding. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a conductive M8 bolt and a conductive M8 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent to M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M8 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M8 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M8 nut and tighten to 22 Nm (16 lb ft). Note: The repair area must be properly refinished to maintain positive electrical grounding. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10170 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a conductive M6 rivet stud and a conductive M6 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new, conductive M6 rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new, conductive M6 rivet stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 16. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). 17. Check for proper system operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10171 Fuse Block: Removal and Replacement 175 Amp Mega Fuse Replacement (Diesel) 175 Amp Mega Fuse Replacement (Diesel) Removal Procedure 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). 2. Remove the mega fuse cover (3). 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10172 5. Remove the auxiliary battery positive cable nut (1) from the mega fuse holder. 6. Remove the generator battery jumper cable to fuse nut (3). 7. Remove the generator battery jumper cable terminal (2) from the fuse stud. 8. Remove the auxiliary battery positive cable from the fuse studs. 9. Remove the upper mega fuse nut (1), if necessary. 10. Remove the appropriate mega fuse (2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10173 1. Install the appropriate mega fuse (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the upper mega fuse nut (1), if necessary. Tighten the nut to 15 Nm (11 lb ft). 3. Install the auxiliary battery positive cable to the fuse studs. 4. Install the generator battery jumper cable terminal (2) to the fuse stud. 5. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 9 Nm (80 lb in). 6. Install the auxiliary battery positive cable nut (1) to the mega fuse holder. Tighten the nut to 15 Nm (11 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10174 7. Install the starter solenoid cable terminal (2) to the fuse stud. 8. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 9. Install the mega fuse cover (3). 10. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). 175 Amp Mega Fuse Replacement (Single Battery) 175 Amp Mega Fuse Replacement (Single Battery) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10175 175 Amp Mega Fuse Replacement (Auxiliary Battery) 175 Amp Mega Fuse Replacement (Auxiliary Battery) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10176 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10177 Instrument Panel Electrical Center or Junction Block Replacement - Left Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10178 Instrument Panel Electrical Center or Junction Block Replacement - Left Side Body Wiring Harness Junction Block Replacement Body Wiring Harness Junction Block Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10179 Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10180 Underhood Electrical Center or Junction Block Bracket Replacement Underhood Electrical Center or Junction Block Bracket Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10181 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10186 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10187 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10188 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10189 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10190 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10191 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10200 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10201 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 10206 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10212 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10213 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10214 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10215 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 10220 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 10221 Multiple Junction Connector: Locations Harness Routing Views Rear Bumper Harness Routing 1 - Rear Bumper 2 - J403 (UD7) 3 - J404 (UD7) 4 - Junction Block - Rear Lamps Connector 5 X408 (UD7) Brake Clutch Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 10222 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chassis Harness (31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 10223 1 - Trailer Brake Control Relay (JL1) 2 - J422 (JL1) 3 - Trailer Connector 4 - J331 (Diesel without NQZ/LY6) 5 - X300 (LY6) 6 - X300 (Diesel) 7 - J411 (JL1) 8 - Junction Block - Rear Lamps 9 G401 10 - J338 (JL1) 11 - G300 12 - J300 (LY6 without NQZ) Passenger Door Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 10224 1 - J604 (YE9 without AN3/DL3) 2 - Junction Block - Right I/P X3 3 - Door Frame 4 - X601 (ASF) 5 - X600 (YE9 without AN3/DL3) 6 - J603 (YE9 without AN3/DL3) I/P Harness Routing - Passenger Compartment (Except HP2) - 1 of 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 10225 1 - X201 2 - X205 3 - Junction Block - Right I/P 4 - X200 5 - X202 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name Multiple Junction Connector: Diagrams Connector End Views By Name Ai - Ba Component Connector End Views (continued) Air Temperature Actuator - Left (CJ2) Air Temperature Actuator - Right (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10228 Air Temperature Actuator (C67 or C42) Air Temperature Sensor - Inside (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10229 Air Temperature Sensor - Lower Left (CJ2) Air Temperature Sensor - Lower Right (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10230 Air Temperature Sensor - Upper Left (CJ2) Air Temperature Sensor - Upper Right (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10231 Ambient Air Temperature Sensor (CJ2 or C67) Ambient Light Sensor (C67, C42 or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10232 Ambient Light/Sunload Sensor (CJ2) Audio Amplifier X1 (UQA with Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10233 Audio Amplifier X1 (UQA without Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10234 Audio Amplifier X2 (UQA) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10235 Audio Amplifier X3 (UQA) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10236 Audio/Video Adapter (U42) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10237 Automatic Transmission Auxiliary Fluid Pump Control Module X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10238 Automatic Transmission Auxiliary Fluid Pump Control Module X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10239 Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10240 Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10241 Automatic Transmission Internal Mode Switch (MW7) Automatic Transmission Shift Lever (M30, MYC, MYD, M99 or MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10242 Automatic Transmission Shift Lock Control Solenoid Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10243 Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X2 (TP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10244 Auxiliary Battery Relay X3 (TP2) Auxiliary Battery Run Relay (TP2) Auxiliary Body Control Module (XBCM) X1 (EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10245 Auxiliary Body Control Module (XBCM) X2 (EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10246 Backup Alarm (8S3) Backup Lamp - Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10247 Backup Lamp - Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10248 Backup Lamp Switch (TZ0) Barometric Pressure (BARO) Sensor (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10249 Battery - Left (-) (Auxiliary Battery Negative Cable) (6A6) Battery - Left (-) (Auxiliary Battery Negative Cable) (TP2) Battery - Left (-) (Battery Negative Cable) (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10250 Battery - Left (+) (Auxiliary Battery Positive Cable) (TP2) Battery - Left (+) (Starter Cable) (6A6 or Diesel) Battery - Right (-) (Battery Negative Cable) (Gas) Battery - Right (-) (Starter Cable) (Diesel) Ba - Da Component Connector End Views (continued) Battery - Right (+) (Diesel or 9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10251 Battery - Right (+) (Gas without 9L4) Battery (+) (Battery Positive Cable) (HP2) Battery (+) (Battery Positive Cable) (HP2) Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10252 Battery Module 1 (HP2) Battery Module 21 (HP2) Battery Module 22 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10253 Battery Module 40 (HP2) Blower Motor Blower Motor Control Module X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10254 Blower Motor Control Module X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10255 Body Control Module (BCM) X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10256 Body Control Module (BCM) X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10257 Body Control Module (BCM) X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10258 Body Control Module (BCM) X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10259 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10260 Body Control Module (BCM) X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10261 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10262 Body Control Module (BCM) X6 Body Control Module (BCM) X7 (except MEX or A52) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10263 Brake Booster Vacuum Sensor (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10264 Brake Fluid Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10265 Brake Master Cylinder Piston Position Sensor (HP2) Brake Master Cylinder Pressure Sensor (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10266 Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10267 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10268 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10269 Cellular Telephone Microphone (UE1, UUL or UUK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10270 Center High Mounted Stop Lamp (CHMSL) X1 Center High Mounted Stop Lamp (CHMSL) X2 Center High Mounted Stop Lamp (CHMSL) X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10271 Center High Mounted Stop Lamp (CHMSL) X4 Central Sequential Fuel Injection (Central SFI) X1-X6 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10272 Central Sequential Fuel Injection (Central SFI) X7 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10273 Chime Module (UL5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10274 Clutch Pedal Position (CPP) Switch (TZ0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10275 Control Solenoid Valve Assembly X1 (MYC, MYD or M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10276 Control Solenoid Valve Assembly X2 (MYC, MYD or M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10277 Control Solenoid Valve Assembly X3 (MYC, MYD or M99) Crankshaft Position (CKP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10278 Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10279 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10280 Data Link Connector (DLC) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10281 Da - Dr Component Connector End Views (continued) Data Link Resistor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10282 Data Link Resistor 2 (HP2) Digital Radio Receiver (U2K) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10283 Digital Video Disc (DVD) Control Module X1 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10284 Digital Video Disc (DVD) Control Module X2 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10285 Digital Video Disc (DVD) Control Module X3 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10286 Digital Video Disc (DVD) Control Module X4 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10287 Digital Video Disc (DVD) Control Module X5 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10288 Digital Video Disc (DVD) Control Module X6 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10289 Digital Video Disc (DVD) Display - Driver Seat Headrest X1 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10290 Digital Video Disc (DVD) Display - Driver Seat Headrest X2 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10291 Digital Video Disc (DVD) Display - Passenger Seat Headrest X1 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10292 Digital Video Disc (DVD) Display - Passenger Seat Headrest X2 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10293 Dome/Reading Lamps - Front Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10294 Dome/Reading Lamps - Rear (Crew Cab or Extended Cab) Door Latch - Driver (AU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10295 Door Latch - Driver (except AU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10296 Door Latch - Left Rear (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10297 Door Latch - Passenger Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10298 Door Latch - Right Rear (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10299 Door Lock Switch - Driver (AU3 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10300 Door Lock Switch - Passenger (AU3 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10301 Door Lock/Window Switch - Driver X1 (AN3 or DL3) Door Lock/Window Switch - Driver X2 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10302 Door Lock/Window Switch - Driver X3 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10303 Door Lock/Window Switch - Driver X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10304 Door Lock/Window Switch - Driver X7 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10305 Door Lock/Window Switch - Passenger X1 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10306 Door Lock/Window Switch - Passenger X2 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10307 Door Lock/Window Switch - Passenger X3 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10308 Door Lock/Window Switch - Passenger X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10309 Door Lock/Window Switch - Passenger X7 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10310 Drive Motor Battery Cable Terminal Extension Cover (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10311 Drive Motor Battery Current Sensor (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10312 Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10313 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10314 Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10315 Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10316 Drive Motor Generator Battery Control Module X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10317 Drive Motor Generator Battery Control Module X3 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10318 Drive Motor Generator Battery Control Module X4 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10319 Drive Motor Generator Battery Control Module X5 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10320 Dr - En Component Connector End Views (continued) Drive Motor Generator Battery X1 (HP2) Drive Motor Generator Battery X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10321 Drive Motor Generator Power Inverter Module Cover (HP2) Drive Motor Generator Power Inverter Module X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10322 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10323 Drive Motor Generator Power Inverter Module X2 (HP2) Drive Motor Generator Power Inverter Module X3 (HP2) Drive Motor Generator Power Inverter Module X4 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10324 Drive Motor Generator Power Inverter Module X5 (HP2) Drive Motor Generator Power Inverter Module X6 (HP2) Drive Motor Generator Power Inverter Module X7 (HP2) Drive Motor Generator Power Inverter Module X8 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10325 Drive Motor Generator Power Inverter Module X9 (HP2) Drive Motor Generator Power Inverter Module X10 (HP2) Drive Motor Generator Power Inverter Module X11 (HP2) Drive Motor Generator Power Inverter Module X12 (HP2) Drive Motor Power Inverter Current Limit Relay X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10326 Drive Motor Power Inverter Current Limit Relay X2 (HP2) Driver Information Center (DIC) Switch (except MEX or 8S8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10327 Electronic Adjustable Pedal (EAP) Assembly (JF4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10328 Electronic Brake Control Module (EBCM) (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10329 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10330 Electronic Brake Control Module (EBCM) (JF3 or JF7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10331 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10332 Electronic Brake Control Module (EBCM) (JH6 or JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10333 Electronic Brake Control Module (EBCM) (JL4 except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10334 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10335 Electronic Brake Control Module (EBCM) (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10336 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10337 Electronic Compass Module (YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10338 Electronic Power Steering Motor Control Module X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10339 Electronic Power Steering Motor Control Module X3 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10340 Electronic Power Steering Motor Control Module X4 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10341 Emergency Vehicle Roof Lamp Relay (5Y0) Engine Control Module (ECM) X1 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10342 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10343 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10344 Engine Control Module (ECM) X1 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10345 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10346 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10347 Engine Control Module (ECM) X1 (LY2, LMG, LC9, LY5, LH6, L76 or L9H) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10348 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10349 Engine Control Module (ECM) X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10350 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10351 Engine Control Module (ECM) X1 (LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10352 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10353 Engine Control Module (ECM) X2 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10354 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10355 En - Fu Component Connector End Views (continued) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10356 Engine Control Module (ECM) X2 (LY2, LY6 or L9H with Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10357 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10358 Engine Control Module (ECM) X2 (LMG, LC9, LY5, LH6, L76 or L9H without Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10359 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10360 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10361 Engine Control Module (ECM) X2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10362 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10363 Engine Control Module (ECM) X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10364 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10365 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10366 Engine Control Module (ECM) X3 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10367 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10368 Engine Coolant Level Switch (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10369 Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10370 Engine Cooling Fan - Left (Gas except LY6) Engine Cooling Fan - Right (Gas except LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10371 Engine Cooling Fan Resistor - Left (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10372 Engine Cooling Fan Resistor - Right (HP2) Engine Oil Level (EOL) Switch (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10373 Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10374 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10375 Evaporative Emission (EVAP) Canister Purge Solenoid Valve (Gas) Evaporative Emission (EVAP) Canister Vent Solenoid Valve (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10376 Evaporator Temperature Sensor (except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10377 Exhaust Gas Recirculation (EGR) Temperature Sensor 1 (Diesel) Exhaust Gas Recirculation (EGR) Temperature Sensor 2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10378 Exhaust Gas Recirculation (EGR) Valve (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10379 Exhaust Pressure Differential Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10380 Exhaust Temperature Sensor 1 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10381 Exhaust Temperature Sensor 2 (Diesel) Fog Lamp - Left Front (T96) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10382 Fog Lamp - Right Front (T96) Front Drive Axle Actuator (NQF, NQG or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10383 Fuel Heater (Diesel) Fuel Injector 1 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10384 Fuel Injector 1 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10385 Fuel Injector 1 (LU3) Fuel Injector 2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10386 Fuel Injector 2 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10387 Fuel Injector 2 (LU3) Fuel Injector 3 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10388 Fuel Injector 3 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10389 Fuel Injector 3 (LU3) Fuel Injector 4 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10390 Fuel Injector 4 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10391 Fuel Injector 4 (LU3) Fuel Injector 5 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10392 Fu - He Component Connector End Views (continued) Fuel Injector 5 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10393 Fuel Injector 5 (LU3) Fuel Injector 6 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10394 Fuel Injector 6 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10395 Fuel Injector 6 (LU3) Fuel Injector 7 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10396 Fuel Injector 7 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10397 Fuel Injector 8 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10398 Fuel Injector 8 (Gas except LU3) Fuel Level Sensor - Primary (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10399 Fuel Level Sensor - Secondary (Diesel with 31 Series without NQZ) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10400 Fuel Pressure Regulator (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10401 Fuel Pressure Sensor (Gas except LU3 or LY6) Fuel Pump/Trailer Brake Control Module (Gas with JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10402 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10403 Fuel Pump (Diesel with 31 Series without NQZ) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10404 Fuel Pump and Sender Assembly - Front (Gas except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10405 Fuel Pump and Sender Assembly - Front (MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10406 Fuel Pump and Sender Assembly - Rear (LY6 except MEX and without NQZ) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10407 Fuel Pump and Sender Assembly - Rear (LY6 with MEX and without NQZ) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10408 Fuel Pump Flow Control Module (Gas except JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10409 Fuel Pump Relay - Secondary (LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10410 Fuel Rail Pressure (FRP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10411 Fuel Tank Pressure (FTP) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10412 Fuel Temperature Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10413 Garage Door Opener (GDO) (UG1) Generator - Auxiliary X1 (Diesel with K76 or YF2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10414 Generator - Auxiliary X2 (Diesel with K76 or YF2) Generator Battery Vent Fan (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10415 Generator Battery Vent Fan Relay (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10416 Generator Control Module Coolant Pump - Left (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10417 Generator Control Module Coolant Pump - Right (HP2) Generator Control Module Temperature Sensor (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10418 Generator X1 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10419 Generator X1 (Gas) Generator X2 (Diesel) Generator X2 (LU3) Generator X2 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10420 Glow Plug Control Module (GPCM) X1 (Diesel) Glow Plug Control Module (GPCM) X2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10421 Headlamp - Left High Beam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10422 Headlamp - Left Low Beam Headlamp - Right High Beam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10423 Headlamp - Right Low Beam Headlamp and Panel Dimmer Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10424 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10425 He - In Component Connector End Views (continued) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (Gas except LU3 and except ZW9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10426 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY6 or L96 with ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10427 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (Gas except LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10428 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (Gas except LU3 and except ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY6 or L96 with ZW9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10429 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10430 Heated Seat Control Module X1 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10431 Heated Seat Control Module X2 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10432 Heated Seat Control Module X3 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10433 Heated Seat Control Module X4 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10434 Heated Seat Element - Driver Back (AN3 without KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10435 Heated Seat Element - Driver Back (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10436 Heated Seat Element - Driver Cushion (AN3 without KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10437 Heated Seat Element - Driver Cushion (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10438 Heated Seat Element - Passenger Back (AN3 without KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10439 Heated Seat Element - Passenger Back (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10440 Heated Seat Element - Passenger Cushion (AN3 without KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10441 Heated Seat Element - Passenger Cushion (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10442 Heated Seat Switch - Driver (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10443 Heated Seat Switch - Passenger (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10444 Heated Steering Wheel (KA9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10445 Heater Coolant Pump (HP2) High Voltage Circuit Impact Detection Sensor (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10446 Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10447 Horn - Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10448 Horn - Right (Z71, YE9 or HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10449 HVAC Control Module X1 (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10450 HVAC Control Module X2 (C67, C42 or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10451 HVAC Control Module X2 (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10452 HVAC Control Module X3 (C67, C42, CJ2 or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10453 Ignition Coil 1 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10454 Ignition Coil 2 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10455 Ignition Coil 3 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10456 Ignition Coil 4 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10457 Ignition Coil 5 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10458 Ignition Coil 6 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10459 Ignition Coil 7 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10460 Ignition Coil 8 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10461 Ignition Control Module (ICM) (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10462 Ignition Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10463 Inflatable Restraint Front End Sensor - Left (10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10464 Inflatable Restraint Front End Sensor - Right (10 Series) Inflatable Restraint Front End Sensor (except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10465 Inflatable Restraint I/P Module (10 Series except MEX) Inflatable Restraint I/P Module (20/30/31 Series or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10466 Inflatable Restraint I/P Module Disable Switch (C99 or MEX) Inflatable Restraint I/P Module Indicator (AL0 or C99 except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10467 Inflatable Restraint Passenger Presence System (PPS) Module (AL0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10468 Inflatable Restraint Roof Rail Module - Driver (Crew Cab with ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10469 Inflatable Restraint Roof Rail Module - Driver (Extended Cab with ASF) In - Ob Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10470 Component Connector End Views (continued) Inflatable Restraint Roof Rail Module - Driver (Regular Cab with ASF) Inflatable Restraint Roof Rail Module - Passenger (Crew Cab with ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10471 Inflatable Restraint Roof Rail Module - Passenger (Extended Cab with ASF) Inflatable Restraint Roof Rail Module - Passenger (Regular Cab with ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10472 Inflatable Restraint Seat Position Sensor - Driver (10 Series except MEX) Inflatable Restraint Seat Position Sensor - Passenger (10 Series except Crew Cab or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10473 Inflatable Restraint Sensing and Diagnostic Module (SDM) X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10474 Inflatable Restraint Sensing and Diagnostic Module (SDM) X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10475 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10476 Inflatable Restraint Side Impact Module - Left (10 Series except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10477 Inflatable Restraint Side Impact Module - Left (HP2) Inflatable Restraint Side Impact Module - Right (10 Series except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10478 Inflatable Restraint Side Impact Module - Right (HP2) Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10479 Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended or Crew Cab with ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10480 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended or Crew Cab with ASF) Inflatable Restraint Steering Wheel Module Coil X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10481 Inflatable Restraint Steering Wheel Module Coil X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10482 Inflatable Restraint Steering Wheel Module X1 (10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10483 Inflatable Restraint Steering Wheel Module X2 (10 Series) Inflatable Restraint Steering Wheel Module (except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10484 Infrared Transmitter (U42) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10485 Inside Rearview Mirror (ISRVM) (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10486 Instrument Panel Cluster (IPC) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10487 Intake Air Heater (IAH) X1 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10488 Intake Air Heater X2 (Diesel) Intake Air Temperature (IAT) Sensor 2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10489 Intake Air Valve (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10490 Knock Sensor (KS) 1 (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10491 Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10492 License Lamp - Left License Lamp - Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10493 Manifold Absolute Pressure (MAP) Sensor (LU3) Manifold Absolute Pressure (MAP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10494 Manifold Absolute Pressure (MAP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10495 Marker Lamp - Tailgate (RO5) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10496 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10497 Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10498 Memory Seat Module (MSM) X3 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10499 Memory Seat Module (MSM) X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10500 Memory Seat Module (MSM) X5 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10501 Memory Seat Module (MSM) X6 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10502 Memory Seat Module (MSM) X7 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10503 Mode Actuator (C67, C42 or CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10504 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Multifunction Switch - I/P (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10505 Noise Compensation Microphone (UQA with Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10506 Object Alarm Sensor - Left Rear Corner (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10507 Ob - Se Component Connector End Views (continued) Object Alarm Sensor - Left Rear Middle (UD7) Object Alarm Sensor - Right Rear Corner (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10508 Object Alarm Sensor - Right Rear Middle (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10509 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10510 Outside Rearview Mirror - Driver (DL3, DL8 or DPN) Outside Rearview Mirror - Passenger (DL3, DL8 or DPN) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10511 Outside Rearview Mirror Switch (DL8 or DPN) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10512 Park Brake Switch Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10513 Park/Turn Signal Lamp - Lower Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10514 Park/Turn Signal Lamp - Lower Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10515 Park/Turn Signal Lamp - Upper Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10516 Park/Turn Signal Lamp - Upper Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10517 Power Steering Assist Motor X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10518 Power Steering Assist Motor X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10519 Power Take Off (PTO) Module (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10520 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10521 Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10522 Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10523 Pressure Control (PC) Solenoid Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10524 Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10525 Pressure Switch Manifold (PSM) (MW7) Radio X1 (except Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10526 Radio X1 (Y91 or 8S8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10527 Radio X2 (except Y91 or 8S8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10528 Radio X2 (Y91 or 8S8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10529 Radio X3 (U42) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10530 Radio X4 (UUL or UUK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10531 Rear Fender Clearance Lamp - Left Front (RO5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10532 Rear Fender Clearance Lamp - Left Rear (RO5) Rear Fender Clearance Lamp - Right Front (RO5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10533 Rear Fender Clearance Lamp - Right Rear (RO5) Rear Object Sensor Control Module X1 (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10534 Rear Object Sensor Control Module X2 (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10535 Rear Seat Audio (RSA) Control X1 (UK6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10536 Rear Seat Audio (RSA) Control X2 (UK6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10537 Rear Window Defogger Grid X1 (C49) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10538 Rear Window Defogger Grid X2 (C49) Rearview Camera (SPO Rearview Camera) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10539 Rearview Camera Image Display Module X1 (UVC) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10540 Rearview Camera Image Display Module X2 (UVC) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10541 Recirculation Actuator (C67 or CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10542 Remote Control Door Lock Receiver (RCDLR) (AP3 or AP8) Roof Beacon Relay (TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10543 Roof Beacon Switch (5X7, 5Y0 or TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10544 Roof Clearance Lamp - Left Front Outer (U01) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10545 Roof Clearance Lamp - Front Middle (U01) Roof Clearance Lamp - Right Front Outer (U01) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10546 Seat Adjuster Motor Assembly - Driver (AG1 without AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10547 Seat Adjuster Motor Assembly - Driver X1 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10548 Se - Sp Component Connector End Views (continued) Seat Adjuster Motor Assembly - Driver X2 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10549 Seat Adjuster Motor Assembly - Passenger (AG2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10550 Seat Adjuster Switch - Driver (AG1 without AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10551 Seat Adjuster Switch - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10552 Seat Adjuster Switch - Passenger (AG2 without AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10553 Seat Adjuster Switch - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10554 Seat Back Ventilation Heating and Cooling Module - Driver (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10555 Seat Back Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10556 Seat Belt Buckle - Driver Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10557 Seat Belt Buckle - Passenger X1 (10 Series without MEX) Seat Belt Buckle - Passenger X2 (AL0) Seat Belt Pretensioner - Driver Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10558 Seat Belt Pretensioner - Passenger Seat Climate Control Module X1 (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10559 Seat Climate Control Module X2 (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10560 Seat Climate Control Module X3 (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10561 Seat Cushion Ventilation Heating and Cooling Module - Driver (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10562 Seat Cushion Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10563 Seat Front Vertical Motor - Driver (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10564 Seat Front Vertical Motor - Passenger (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10565 Seat Horizontal Motor - Driver (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10566 Seat Horizontal Motor - Passenger (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10567 Seat Lumbar Horizontal Motor - Driver (AN3) Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10568 Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) Seat Lumbar Switch - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10569 Seat Lumbar Switch - Passenger (AN3) Seat Lumbar Vertical Motor - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10570 Seat Lumbar Vertical Motor - Passenger (AN3) Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10571 Seat Rear Vertical Motor - Driver (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10572 Seat Rear Vertical Motor - Passenger (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10573 Seat Recline Motor - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10574 Seat Recline Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10575 Seat Recline Position Sensor - Driver (AN3) Security Indicator Lamp (SPO Alarm) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10576 Serial Data Gateway (SDG) Module X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10577 Serial Data Gateway (SDG) Module X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10578 Shift Solenoid (SS) Valve 1 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10579 Shift Solenoid (SS) Valve 2 (MW7) Shift Solenoid (SS) Valve 3 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10580 Side Marker Lamp - Left Front (Z88) Side Marker Lamp - Left Rear (Z88) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10581 Side Marker Lamp - Right Front (Z88) Side Marker Lamp - Right Rear (Z88) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10582 Sliding Rear Window Close Relay (A48) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10583 Sliding Rear Window Motor (A48) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10584 Sliding Rear Window Open Relay (A48) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10585 Sliding Rear Window Switch (A48) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10586 Speaker - Center I/P (UQA with Y91) Speaker - Left Front (UQ3) Speaker - Left Front (UQ5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10587 Speaker - Left Front (UQA) Sp - Tr Component Connector End Views (continued) Speaker - Left Front Tweeter (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10588 Speaker - Left Rear (Extended Cab or Crew Cab with UQ3 or UQ5) Speaker - Left Rear (Extended Cab or Crew Cab with UQA) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10589 Speaker - Left Rear (Regular Cab) Speaker - Right Front (UQ3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10590 Speaker - Right Front (UQ5) Speaker - Right Front (UQA) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10591 Speaker - Right Front Tweeter (except MEX) Speaker - Right Rear (Extended Cab or Crew Cab with UQ3 or UQ5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10592 Speaker - Right Rear (Extended Cab or Crew Cab with UQA) Speaker - Right Rear (Regular Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10593 Speaker - Subwoofer (UQA) Starter Motor X1 (5X7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10594 Starter Motor X1 (LU3 without 9L4) Starter Motor X1 (6A6) Starter Motor X1 (9L4 or Gas except LU3) Starter Motor X1 (Diesel) Starter Motor X2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10595 Starter Motor X2 (Gas) Steering Angle Sensor (JL4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10596 Steering Wheel Control Switch - Left (K34 or KA9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10597 Steering Wheel Control Switch - Right (UK3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10598 Stop Lamp Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10599 Sunroof Control Module (CF5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10600 Sunroof Switch (CF5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10601 Sunshade - Left (DH6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10602 Sunshade - Right (DH6) Tail/Stop and Turn Signal Lamp - Lower Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10603 Tail/Stop and Turn Signal Lamp - Lower Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10604 Tail/Stop and Turn Signal Lamp - Upper Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10605 Tail/Stop and Turn Signal Lamp - Upper Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10606 Theft Deterrent Module (TDM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10607 Throttle Body (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10608 Throttle Body (Gas except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10609 Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10610 Torque Converter Clutch (TCC) Solenoid Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10611 Wiring Diagram Trailer Brake Control Module (JL1 except 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10612 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10613 Trailer Brake Control Module (JL1 with 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10614 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10615 Trailer Brake Control Relay (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10616 Trailer Brake Control Switch (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10617 Trailer Connector (except MEX or EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10618 Trailer Stop/Turn Relay (TZ0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10619 Tr - Ya Component Connector End Views (continued) Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10620 Transfer Case Encoder Motor (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10621 Transfer Case Shift Control Module X1 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10622 Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10623 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10624 Transfer Case Shift Control Switch (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10625 Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10626 Transmission Control Module (TCM) (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10627 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10628 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10629 Transmission Power Inverter Module (3 Phase) Cable Cover (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10630 Turbocharger Vane Position Control Solenoid Valve (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10631 Turbocharger Vane Position Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10632 Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Turn Signal/Multifunction Switch X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10633 Valve Lifter Oil Manifold (VLOM) Assembly (LMG, LC9, LZ1 or L96) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10634 Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10635 Vehicle Communication Interface Module (VCIM) X3 (UE1 with UUL or UUK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10636 Vehicle Inclination Sensor (SPO Alarm) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10637 Vehicle Shock Sensor (SPO Alarm) Vehicle Speed Sensor (VSS) (M30, TZ0, MYC and MW7or M99 with NQG or NQF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10638 Vehicle Speed Sensor (VSS) (MW7 except NQG or NQF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10639 Video Display (U42) Water in Fuel Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10640 Wheel Speed Sensor (WSS) - Left Front (10 Series) Wheel Speed Sensor (WSS) - Left Front (except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10641 Wheel Speed Sensor (WSS) - Left Rear (JL4 or HP2) Wheel Speed Sensor (WSS) - Right Front (10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10642 Wheel Speed Sensor (WSS) - Right Front (except 10 Series) Wheel Speed Sensor (WSS) - Right Rear (JL4 or HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10643 Window Motor - Driver (A31) Window Motor - Left Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10644 Window Motor - Passenger (A31) Window Motor - Right Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10645 Window Switch - Driver X1 (A31 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10646 Window Switch - Driver X2 (A31 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10647 Window Switch - Left Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10648 Window Switch - Passenger (A31 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10649 Window Switch - Right Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10650 Windshield Outside Moisture Sensor (CE1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10651 Windshield Washer Fluid Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10652 Windshield Washer Fluid Pump Windshield Wiper Motor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10653 Wrecker Relay X1 (5X7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10654 Wrecker Relay X2 (5X7) Yaw and Lateral Accelerometer Sensor (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10655 Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10656 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10657 1-2 Shift - Ac Component Connector End Views 1-2 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10658 2-3 Shift Solenoid (SS) Valve (M30) A/C Compressor Clutch (C67) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10659 A/C Compressor Clutch (CJ2) A/C Compressor X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10660 A/C Compressor X2 (+) (HP2) A/C Compressor X3 (-) (HP2) A/C Low Pressure Sensor (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10661 A/C Refrigerant Pressure Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10662 A/C Refrigerant Pressure Sensor (Gas except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10663 A/C Refrigerant Pressure Sensor (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10664 Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10665 Accessory DC Power Control Module X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10666 Accessory DC Power Control Module X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10667 Accessory DC Power Control Module X3 (HP2) Accessory DC Power Control Module X4 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10668 Accessory Power Outlet - Center Console (D07) Accessory Power Outlet - Center Console Compartment (D07) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10669 Accessory Power Outlet - Center Seat (AZ3) Accessory Power Outlet - I/P 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10670 Accessory Power Outlet - I/P 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10671 Multiple Junction Connector: Diagrams Connector End Views By Number X100 Inline Harness Connector End Views X100 Forward Lamp Harness to Left Front Headlamp Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10672 X102 Inline Harness Connector End Views X102 Brake Clutch Harness to Chassis Harness (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10673 X103 Inline Harness Connector End Views X103 Instrument Panel Harness to Forward Lamp Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10674 X106 Inline Harness Connector End Views X106 Forward Lamp Harness to Right Front Headlamp Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10675 X107 Inline Harness Connector End Views X107 Engine Chassis Harness to Engine Harness (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10676 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10677 X108 Inline Harness Connector End Views X108 Engine Chassis Harness to Engine Harness (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10678 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10679 X109 Inline Harness Connector End Views X109 Engine Harness (LU3) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (LU3 or Diesel without NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10680 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10681 X109 Engine Harness (except Diesel) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (HP2, LU3 or Diesel with NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10682 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10683 X109 Engine Harness to Instrument Panel Harness (Gas except LU3 and without NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10684 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10685 X109 Engine Harness to Instrument Panel Harness (Gas except LU3 and with NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10686 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10687 X110 Inline Harness Connector End Views X110 Engine Harness (except Diesel) or Engine Chassis Harness (Diesel) to Front Axle Harness (NQF, NQG or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10688 X111 Inline Harness Connector End Views X111 Engine Harness to Left Ignition Coil Harness (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10689 X112 Inline Harness Connector End Views X112 Engine Harness to Camshaft Position Sensor Jumper Harness (L20, LMG or LC9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10690 X112 Engine Harness to Camshaft Position Sensor Jumper Harness (LU3) X112 Engine Harness to Camshaft Position Sensor Jumper Harness (LZ1, LY6, L96 or L9H) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10691 X113 Inline Harness Connector End Views X113 Engine Harness to Right Ignition Coil Harness (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10692 X113 Engine Jumper Harness to Engine Harness (Diesel) X115 Inline Harness Connector End Views X115 Chassis Harness to Instrument Panel Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10693 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10694 X116 Inline Harness Connector End Views X116 Battery Positive Harness to Brake Clutch Harness (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10695 X117 Inline Harness Connector End Views X117 Fuel Rail Pressure Sensor Jumper Harness to Engine Harness (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10696 X120 Inline Harness Connector End Views X120 Engine Harness to Forward Lamp Harness (HP2) X121 Inline Harness Connector End Views X121 Battery Negative Harness to Battery Positive Harness (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10697 X124 Inline Harness Connector End Views X124 Engine Chassis Harness to PTO Jumper Harness (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10698 X125 Inline Harness Connector End Views X125 Heated Oxygen Sensor (HO2S) Jumper Harness to Engine Harness (LY6 with 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10699 X127 Inline Harness Connector End Views X127 Engine Chassis Harness to Generator Jumper Harness (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10700 X128 Inline Harness Connector End Views X128 Fuel Pressure Regulator Harness to Engine Harness (Diesel) X129 Inline Harness Connector End Views X129 Instrument Panel Harness to Chassis Harness (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10701 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10702 X131 Inline Harness Connector End Views X131 Chassis Harness to Engine Harness (LU3) X131 Chassis Harness to Engine Harness (L20, LMG, LC9 or L9H) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10703 X150 Inline Harness Connector End Views X150 Engine Harness to Instrument Panel Harness (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10704 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10705 X122 Inline Harness Connector End Views X122 Auxiliary Battery Harness to Engine Harness (TP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10706 X123 Inline Harness Connector End Views X123 Engine Chassis Harness to Instrument Panel Harness (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10707 X175 Inline Harness Connector End Views X175 Engine Chassis Harness to Transmission Internal Harness (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10708 X175 Engine Harness to Transmission Internal Harness (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10709 X176 Inline Harness Connector End Views X176 Engine Harness to Transmission Harness (M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10710 X200 Inline Harness Connector End Views X200 Instrument Panel Harness to Body Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10711 X201 Inline Harness Connector End Views X201 Steering Column Harness to Instrument Panel Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10712 X202 Inline Harness Connector End Views X202 Instrument Panel Harness to Body Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10713 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10714 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10715 X203 Inline Harness Connector End Views X203 Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) to Headliner Harness (UE1, UUL or UUK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10716 X204 Inline Harness Connector End Views X204 Headliner Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) (U42) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10717 X205 Inline Harness Connector End Views X205 Brake Clutch Harness to Instrument Panel Harness (except TZ0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10718 X205 Brake Clutch Harness to Instrument Panel Harness (TZ0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10719 X206 Inline Harness Connector End Views X206 Right A-Pillar Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) (U42) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10720 X207 Inline Harness Connector End Views X207 Instrument Panel Harness to Instrument Panel Harness (6J4) X208 Inline Harness Connector End Views X208 Body Harness to Headliner Harness (YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10721 X209 Inline Harness Connector End Views X209 Rearview Camera Chassis Harness to Rearview Camera I/P Jumper Harness (SPO Rearview Camera) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10722 X210 Inline Harness Connector End Views X210 Rearview Camera I/P Jumper Harness to Rearview Camera I/P Jumper Extension Harness (SPO Rearview Camera with KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10723 X212 Inline Harness Connector End Views X212 Instrument Panel Harness to I/P Extension Harness (except Y91, MEX or 8S8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10724 X214 Inline Harness Connector End Views X214 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) X215 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10725 Inline Harness Connector End Views X215 Body Harness to Instrument Panel Harness (HP2) X219 Inline Harness Connector End Views X219 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10726 X224 Inline Harness Connector End Views X224 Brake Clutch Harness to Beacon Harness (5Y0 or 5X7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10727 X225 Inline Harness Connector End Views X225 Brake Clutch Harness to Battery Positive Harness (9L4) X226 Inline Harness Connector End Views X226 Fuse Block Jumper Harness to Brake Clutch Harness (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10728 X227 Inline Harness Connector End Views X227 LED Indicator Harness to SPO Theft Harness (SPO Alarm) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10729 X228 Inline Harness Connector End Views X228 Beacon Harness to Chassis Harness (5Y0) X240 Inline Harness Connector End Views X240 I/P Extension Harness to Instrument Panel Harness (UVC except Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10730 X241 Inline Harness Connector End Views X241 Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) to Body Harness (UVC with DRC or DD8) X275 Inline Harness Connector End Views X275 Inflatable Restraint Steering Wheel Module Coil to Body Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10731 X276 Inline Harness Connector End Views X276 Inflatable Restraint Steering Wheel Module Coil to Steering Column Harness (KA9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10732 X277 Inline Harness Connector End Views X277 Inflatable Restraint Steering Wheel Module Coil to Heated Steering Wheel Harness (KA9) X278 Inline Harness Connector End Views X278 Instrument Panel Harness to Body Harness (MEX or A52) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10733 X279 Inline Harness Connector End Views X279 Instrument Panel Harness to Headliner Harness (MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10734 X300 Inline Harness Connector End Views X300 Chassis Harness to Engine Chassis Harness (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10735 X300 Engine Harness to Chassis Harness (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10736 X300 Chassis Harness to Engine Harness (LY6 or L96) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10737 X301 Inline Harness Connector End Views X301 Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) to Console Harness (Y91, UQA or D07) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10738 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10739 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10740 X303 Inline Harness Connector End Views X303 Body Harness to Driver Seat Harness (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10741 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10742 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10743 X303 Body Harness to Driver Seat Harness (except AN3 or MEX) X303 Driver Seat Harness to Body Harness (MEX or A52) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10744 X304 Inline Harness Connector End Views X304 Headliner Harness to Overhead Console Harness (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10745 X305 Inline Harness Connector End Views X305 Body Harness to Passenger Seat Harness (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10746 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10747 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10748 X305 Body Harness to Passenger Seat Harness (except AN3 or MEX) X306 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10749 Inline Harness Connector End Views X306 Headliner Harness to Right A-Pillar Harness (U42) X309 Inline Harness Connector End Views X309 Body Harness to Console Harness (Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10750 X313 Inline Harness Connector End Views X313 Sunroof Harness (CF5) or Overhead Console Harness (TRW, 5X7 or 5Y0) to Right A-Pillar Harness (CF5, TRW, 5X7 or 5Y0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10751 X318 Inline Harness Connector End Views X318 Headliner Harness to CHMSL Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10752 X319 Inline Harness Connector End Views X319 Body Harness to Console Harness (HP2, AZ3 or D07 with UQ3) X320 Inline Harness Connector End Views X320 Body Harness to Sliding Rear Window Jumper Harness (A48) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10753 X324 Inline Harness Connector End Views X324 Driver Seat Harness to Driver Seat Jumper Harness (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10754 X325 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10755 Inline Harness Connector End Views X325 Passenger Seat Harness to Passenger Seat Jumper Harness (AN3) X330 Inline Harness Connector End Views X330 Heated Seat Body Harness to Heated Driver Seat Harness (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10756 X331 Inline Harness Connector End Views X331 Heated Seat Body Harness to Heated Driver Seat Harness (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10757 X332 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10758 Inline Harness Connector End Views X332 Heated Passenger Seat Harness to Heated Seat Body Harness (SPO Heated Seats) X333 Inline Harness Connector End Views X333 Heated Seat Body Harness to Heated Seat Body Harness (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10759 X334 Inline Harness Connector End Views X334 Heated Seat Body Harness to Heated Seat Body Harness (SPO Heated Seats) X350 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10760 Inline Harness Connector End Views X350 Body Harness to Drive Motor Generator Battery Control Harness (HP2) X371 Inline Harness Connector End Views X371 SPO Accessory Signal Cable 1A to SPO Accessory Signal Cable 3A (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10761 X372 Inline Harness Connector End Views X372 SPO Accessory Signal Cable 2B to SPO Accessory Signal Cable 3B (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10762 X373 Inline Harness Connector End Views X373 SPO Accessory Signal Cable 2A to SPO Accessory Signal Cable 3A (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10763 X374 Inline Harness Connector End Views X374 SPO Accessory Signal Cable 1B to SPO Accessory Signal Cable 3B (SPO DVD) X414 Inline Harness Connector End Views X414 Chassis Harness to Camper Harness (UY2 or 8S3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10764 X415 Inline Harness Connector End Views X415 Rear Bumper Harness to Left Hip Lamp Harness (RO5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10765 X451 Inline Harness Connector End Views X451 Body Ground Jumper Harness to Rear Axle Ground Jumper Harness (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10766 X408 Inline Harness Connector End Views X408 Chassis Harness to Rear Bumper Harness (UD7) X416 Inline Harness Connector End Views X416 Rear Bumper Harness to Right Hip Lamp Harness (RO5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10767 X500 Inline Harness Connector End Views X500 Left Front Door Harness to Body Harness (YE9 or HP2, without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10768 X501 Inline Harness Connector End Views X501 Left Front Door Harness to Body Harness (YE9 or HP2, without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10769 X502 Inline Harness Connector End Views X502 Left Front Door Harness to Body Harness (ASF with AN3 or DL3, and except YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10770 X600 Inline Harness Connector End Views X600 Right Front Door Harness to Body Harness (YE9 or HP2, without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10771 X601 Inline Harness Connector End Views X601 Right Front Door Harness to Body Harness (ASF) X700 - X799 Inline Harness Connector End Views X700 Body Harness to Left Rear Door Harness (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10772 X700 Left Rear Door Harness to Body Harness (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10773 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10774 X800 - X899 Inline Harness Connector End Views X800 Body Harness to Right Rear Door Harness (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10775 X800 Right Rear Door Harness to Body Harness (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10776 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10777 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 10782 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 10783 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 10789 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 10790 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10795 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10796 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10797 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10798 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10799 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10800 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10801 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10802 Fuse Block - Underhood Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10803 Fuse Block - Underhood X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10804 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10805 Fuse Block - Underhood X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10806 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10807 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10808 Fuse Block - Underhood X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10809 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10810 Fuse Block - Underhood X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10811 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10812 Fuse Block - Underhood X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10813 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10814 Fuse Block - Underhood X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10815 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10816 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10817 Relay Box: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10818 Fuse Block - I/P Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10819 Fuse Block - I/P Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10820 Fuse Block - I/P X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10821 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10822 Fuse Block - I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10823 Fuse Block - I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10824 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10825 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10826 Relay Box: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10827 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10828 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10833 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10834 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10835 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10836 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10837 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10838 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10839 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10840 Fuse Block - Underhood Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10841 Fuse Block - Underhood X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10842 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10843 Fuse Block - Underhood X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10844 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10845 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10846 Fuse Block - Underhood X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10847 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10848 Fuse Block - Underhood X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10849 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10850 Fuse Block - Underhood X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10851 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10852 Fuse Block - Underhood X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10853 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10854 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10855 Relay Box: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10856 Fuse Block - I/P Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10857 Fuse Block - I/P Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10858 Fuse Block - I/P X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10859 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10860 Fuse Block - I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10861 Fuse Block - I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10862 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10863 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10864 Relay Box: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10865 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 10866 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 10157 > May > 10 > Campaign - Engine Harness Connection Not Latched Wiring Harness: Recalls Campaign - Engine Harness Connection Not Latched SERVICE UPDATE Bulletin No.: 10157 Date: May 24, 2010 Subject: 10157 - Service Update for Inventory and Customer Vehicles - Chassis-to-Engine Harness Connection Not Latched - Expires with Base Warranty Models: 2010 Chevrolet Silverado 2010 GMC Sierra 1500 Series This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to inspect the connection of the chassis-to-engine wire harness connection. If the chassis 12-way connector is not fully seated, connected and latched to the mating engine harness connector, it could create an electrical issue that would be difficult for technicians to diagnose. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers using WINS) or the Investigate Vehicle History link (dealers using GWM). Not all vehicles within the above breakpoints may be involved. Parts Information No parts are required for this update. Service Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 10157 > May > 10 > Campaign - Engine Harness Connection Not Latched > Page 10875 1. Locate the chassis 12-way connector (1). The connector is located on the top of the driver's side shock tower. Refer to illustration. 2. Determine if the chassis 12-way connector is fully seated, connected and latched to the mating engine harness connector. - If the 12-way connector is properly connected, no further action is required. - If the 12-way connector is NOT properly connected, proceed to Step 3. 3. Carefully remove the 12-way connector from the shock tower. 4. Seat the 12-way connector face (2) as shown in illustration. 5. Reconnect the 12-way connector. Ensure that the connector is fully seated, connected and latched to the mating engine harness connector. 6. Re-install the 12-way connector on the shock tower. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's Wiring Harness: Customer Interest Restraint System - Air Bag Warning Lamp On Repeat DTC's TECHNICAL Bulletin No.: 11-09-41-002 Date: March 17, 2011 Subject: Air Bag Warning Lamp Illuminated, Repeat History DTC B0083 0F - B0088 0F (Follow SI and Procedure Outlined Below if necessary) Models: 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT, Escalade Hybrid 2010-2011 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2010-2011 GMC Sierra, Sierra Denali, Sierra Hybrid, Yukon, Yukon XL, Yukon XL Denali, Yukon Hybrid, Yukon Denali Hybrid Condition In extremely rare cases, some customers may comment that the air bag warning lamp is illuminated. This condition may be intermittent and when checking the vehicle for DTCs, the SDM may report B0083, B0084, B0085, B0086, B0087 and/or B0088 with symptom code 0F. The code will be stored in history and may be repeated. The code probably will not be current. Cause This condition may be caused by possible electro-magnetic interference (EMI) in the Amarillo, Texas area from external sources such as aviation airspace traffic radar, creating erratic sensor information to the SDM. Correction Perform all diagnostics and repairs documented in SI. Notice If published SI repair information does not resolve the condition, perform the procedure below. Install a steward clamp ferrite bead following the procedure below: 1. Disconnect battery. Refer to SIR Disabling and Enabling in SI. 2. Remove the door trim. Refer to SI door trim removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's > Page 10881 3. Install the steward clamp ferrite bead on the wire harness (1). 4. Place tape around the steward clamp ferrite bead (1) to avoid vibration or movement. Verify that the door glass does not come in contact with it. 5. Reinstall the door trim. Refer to SI door trim removal. 6. Reconnect the battery. Refer to SIR Disabling and Enabling in SI. Parts Information Parts (Laird HFA100049-0A2) can be purchased from Digi-Key Corporation at www.digikey.com. Material allowance for repair is $1.10 each (in Canada, $1.21). Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative > Page 10886 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10891 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10892 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10893 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10894 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10899 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10900 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10901 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 10906 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative > Page 10911 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-45-002A > May > 10 > Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: Customer Interest Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-45-002A > May > 10 > Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: Customer Interest Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's Wiring Harness: All Technical Service Bulletins Restraint System - Air Bag Warning Lamp On Repeat DTC's TECHNICAL Bulletin No.: 11-09-41-002 Date: March 17, 2011 Subject: Air Bag Warning Lamp Illuminated, Repeat History DTC B0083 0F - B0088 0F (Follow SI and Procedure Outlined Below if necessary) Models: 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT, Escalade Hybrid 2010-2011 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2010-2011 GMC Sierra, Sierra Denali, Sierra Hybrid, Yukon, Yukon XL, Yukon XL Denali, Yukon Hybrid, Yukon Denali Hybrid Condition In extremely rare cases, some customers may comment that the air bag warning lamp is illuminated. This condition may be intermittent and when checking the vehicle for DTCs, the SDM may report B0083, B0084, B0085, B0086, B0087 and/or B0088 with symptom code 0F. The code will be stored in history and may be repeated. The code probably will not be current. Cause This condition may be caused by possible electro-magnetic interference (EMI) in the Amarillo, Texas area from external sources such as aviation airspace traffic radar, creating erratic sensor information to the SDM. Correction Perform all diagnostics and repairs documented in SI. Notice If published SI repair information does not resolve the condition, perform the procedure below. Install a steward clamp ferrite bead following the procedure below: 1. Disconnect battery. Refer to SIR Disabling and Enabling in SI. 2. Remove the door trim. Refer to SI door trim removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's > Page 10925 3. Install the steward clamp ferrite bead on the wire harness (1). 4. Place tape around the steward clamp ferrite bead (1) to avoid vibration or movement. Verify that the door glass does not come in contact with it. 5. Reinstall the door trim. Refer to SI door trim removal. 6. Reconnect the battery. Refer to SIR Disabling and Enabling in SI. Parts Information Parts (Laird HFA100049-0A2) can be purchased from Digi-Key Corporation at www.digikey.com. Material allowance for repair is $1.10 each (in Canada, $1.21). Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative > Page 10930 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10935 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10936 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10937 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10938 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10943 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10944 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10945 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10950 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10951 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10952 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10953 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10954 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10955 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 10960 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10157 > May > 10 > Campaign - Engine Harness Connection Not Latched Wiring Harness: All Technical Service Bulletins Campaign - Engine Harness Connection Not Latched SERVICE UPDATE Bulletin No.: 10157 Date: May 24, 2010 Subject: 10157 - Service Update for Inventory and Customer Vehicles - Chassis-to-Engine Harness Connection Not Latched - Expires with Base Warranty Models: 2010 Chevrolet Silverado 2010 GMC Sierra 1500 Series This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to inspect the connection of the chassis-to-engine wire harness connection. If the chassis 12-way connector is not fully seated, connected and latched to the mating engine harness connector, it could create an electrical issue that would be difficult for technicians to diagnose. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers using WINS) or the Investigate Vehicle History link (dealers using GWM). Not all vehicles within the above breakpoints may be involved. Parts Information No parts are required for this update. Service Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10157 > May > 10 > Campaign - Engine Harness Connection Not Latched > Page 10965 1. Locate the chassis 12-way connector (1). The connector is located on the top of the driver's side shock tower. Refer to illustration. 2. Determine if the chassis 12-way connector is fully seated, connected and latched to the mating engine harness connector. - If the 12-way connector is properly connected, no further action is required. - If the 12-way connector is NOT properly connected, proceed to Step 3. 3. Carefully remove the 12-way connector from the shock tower. 4. Seat the 12-way connector face (2) as shown in illustration. 5. Reconnect the 12-way connector. Ensure that the connector is fully seated, connected and latched to the mating engine harness connector. 6. Re-install the 12-way connector on the shock tower. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative > Page 10970 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-08-45-002A > May > 10 > Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: All Technical Service Bulletins Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-08-45-002A > May > 10 > Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: All Technical Service Bulletins Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's Wiring Harness: All Technical Service Bulletins Restraint System - Air Bag Warning Lamp On Repeat DTC's TECHNICAL Bulletin No.: 11-09-41-002 Date: March 17, 2011 Subject: Air Bag Warning Lamp Illuminated, Repeat History DTC B0083 0F - B0088 0F (Follow SI and Procedure Outlined Below if necessary) Models: 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT, Escalade Hybrid 2010-2011 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2010-2011 GMC Sierra, Sierra Denali, Sierra Hybrid, Yukon, Yukon XL, Yukon XL Denali, Yukon Hybrid, Yukon Denali Hybrid Condition In extremely rare cases, some customers may comment that the air bag warning lamp is illuminated. This condition may be intermittent and when checking the vehicle for DTCs, the SDM may report B0083, B0084, B0085, B0086, B0087 and/or B0088 with symptom code 0F. The code will be stored in history and may be repeated. The code probably will not be current. Cause This condition may be caused by possible electro-magnetic interference (EMI) in the Amarillo, Texas area from external sources such as aviation airspace traffic radar, creating erratic sensor information to the SDM. Correction Perform all diagnostics and repairs documented in SI. Notice If published SI repair information does not resolve the condition, perform the procedure below. Install a steward clamp ferrite bead following the procedure below: 1. Disconnect battery. Refer to SIR Disabling and Enabling in SI. 2. Remove the door trim. Refer to SI door trim removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's > Page 10984 3. Install the steward clamp ferrite bead on the wire harness (1). 4. Place tape around the steward clamp ferrite bead (1) to avoid vibration or movement. Verify that the door glass does not come in contact with it. 5. Reinstall the door trim. Refer to SI door trim removal. 6. Reconnect the battery. Refer to SIR Disabling and Enabling in SI. Parts Information Parts (Laird HFA100049-0A2) can be purchased from Digi-Key Corporation at www.digikey.com. Material allowance for repair is $1.10 each (in Canada, $1.21). Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative > Page 10989 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10994 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10995 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11000 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11001 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11002 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11007 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11008 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11009 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11010 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11011 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11012 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 11017 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative > Page 11022 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 08-08-45-002A > May > 10 > Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: All Technical Service Bulletins Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 08-08-45-002A > May > 10 > Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: All Technical Service Bulletins Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11036 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11037 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11038 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11039 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11040 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11041 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10157 > May > 10 > Campaign - Engine Harness Connection Not Latched Wiring Harness: All Technical Service Bulletins Campaign - Engine Harness Connection Not Latched SERVICE UPDATE Bulletin No.: 10157 Date: May 24, 2010 Subject: 10157 - Service Update for Inventory and Customer Vehicles - Chassis-to-Engine Harness Connection Not Latched - Expires with Base Warranty Models: 2010 Chevrolet Silverado 2010 GMC Sierra 1500 Series This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to inspect the connection of the chassis-to-engine wire harness connection. If the chassis 12-way connector is not fully seated, connected and latched to the mating engine harness connector, it could create an electrical issue that would be difficult for technicians to diagnose. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers using WINS) or the Investigate Vehicle History link (dealers using GWM). Not all vehicles within the above breakpoints may be involved. Parts Information No parts are required for this update. Service Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10157 > May > 10 > Campaign - Engine Harness Connection Not Latched > Page 11046 1. Locate the chassis 12-way connector (1). The connector is located on the top of the driver's side shock tower. Refer to illustration. 2. Determine if the chassis 12-way connector is fully seated, connected and latched to the mating engine harness connector. - If the 12-way connector is properly connected, no further action is required. - If the 12-way connector is NOT properly connected, proceed to Step 3. 3. Carefully remove the 12-way connector from the shock tower. 4. Seat the 12-way connector face (2) as shown in illustration. 5. Reconnect the 12-way connector. Ensure that the connector is fully seated, connected and latched to the mating engine harness connector. 6. Re-install the 12-way connector on the shock tower. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11052 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11053 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11054 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11055 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11056 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11057 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11058 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11059 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11060 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11061 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11062 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11063 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11064 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11065 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11066 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11067 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11068 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11069 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11070 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11071 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11072 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11073 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11074 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11075 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11076 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11077 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11078 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11079 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11080 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11081 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11082 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11083 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11084 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11085 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11086 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11087 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11088 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11089 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11090 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11091 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11092 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11093 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11094 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11095 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11096 Auxiliary Power Outlet: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11097 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11098 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11099 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11100 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11101 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11102 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11103 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11104 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11105 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11106 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11107 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11108 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11109 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11110 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11111 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11112 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11113 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11114 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11115 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11116 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11117 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11118 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11119 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11120 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11121 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11122 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11123 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11124 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11125 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11126 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11127 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11128 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11129 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11130 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11131 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11132 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11133 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11134 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11135 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11136 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11137 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11138 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11139 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11140 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11141 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11142 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11143 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11144 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11145 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11146 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11147 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11148 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11149 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11150 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11151 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11152 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11153 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11154 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11155 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11156 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11157 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11158 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11159 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11160 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11161 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11162 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11163 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11164 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11165 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11166 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11167 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11168 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11169 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11170 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11171 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11172 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11173 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11174 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11175 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11176 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11177 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11178 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11179 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11180 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11181 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11182 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11183 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11184 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11185 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11186 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11187 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11188 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11189 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11190 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11191 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11192 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11193 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11194 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11195 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11196 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11197 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11198 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11199 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11200 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11201 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11202 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11203 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11204 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11205 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11206 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11207 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11208 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11209 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11210 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11211 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11212 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11213 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11214 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11215 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11216 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11217 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11218 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11219 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11220 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11221 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11222 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11223 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11224 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11225 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11226 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11227 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11228 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11229 Auxiliary Power Outlet: Connector Views Component Connector End Views Accessory Power Outlet - Center Console (D07) Accessory Power Outlet - Center Console Compartment (D07) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11230 Accessory Power Outlet - Center Seat (AZ3) Accessory Power Outlet - I/P 1 Accessory Power Outlet - I/P 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11231 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11232 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Power Outlet Schematics Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 11233 Auxiliary Power Outlet: Description and Operation Power Outlets Description and Operation 12 Volt Power Outlet Receptacle Description and Operation The accessory power receptacles are supplied battery voltage at all times. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets Auxiliary Power Outlet: Testing and Inspection Symptoms - Power Outlets Symptoms - Power Outlets Visual/Physical Inspection * Inspect for aftermarket devices which can affect the operation of the power outlets. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories) * Inspect the accessible system components or the visible system components for obvious damage or for obvious conditions which can cause the symptom. Intermittent Electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) Symptom List Refer to Power Outlet Receptacle Malfunction (See: Power Outlet Receptacle Inoperative (120 VAC)) in order to diagnose the system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets > Page 11236 Auxiliary Power Outlet: Testing and Inspection Power Outlet Receptacle Inoperative (120 VAC) Power Outlet Receptacle Malfunction Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The accessory power receptacles are supplied B+ all the time. Reference Information Schematic Reference Cigar Lighter/Power Outlet Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Power Outlets Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the appropriate X80 accessory power receptacle. 2. Test for less than 5 ohm between the ground circuit terminal C and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Verify that a test lamp illuminate between the B+ circuit terminal A and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. 4. If all circuits test normal, test or replace the X80 accessory power receptacle. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets > Page 11237 Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement (See: Service and Repair) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Page 11238 Auxiliary Power Outlet: Service and Repair Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Tools Required J 42059 Cigar Lighter Socket Remover Removal Procedure 1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle: 1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the front of the receptacle. The J 42059 pushes the plastic latches from these tab windows and the receptacle can be pulled straight out. 2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit straight into the receptacle. Angle the J 42059 slightly for insertion into the receptacle. 3. Insert the other side of the "T" into the opposite tab window. You must move the J 42059 handle toward horizontal to engage the other tab window. 4. Use the J 42059 to pull the receptacle straight out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Page 11239 3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. Installation Procedure 1. Route the connector through the retainer. Align the accessory power receptacle retainer to the slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer. Install the accessory power receptacle by pressing into place until fully seated. 5. Install the accessory power receptacle fuse. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Page 11240 Auxiliary Power Outlet: Tools and Equipment Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 11249 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 11255 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual Fuse: Locations Center Instrument Panel Fuse Block - Owners Manual CENTER INSTRUMENT PANEL FUSE BLOCK The center instrument panel fuse block is located underneath the instrument panel, to the left of the steering column. TOP VIEW HARNESS CONNECTOR - USAGE BODY 2 ............................................................................................................................................... ................................... Body Harness Connector 2 BODY 1 ............................................................... ................................................................................................................... Body Harness Connector 1 BODY 3 ............................................................................................................................................ ...................................... Body Harness Connector 3 HEADLINER 3 .................................................. .............................................................................................................. Headliner Harness Connector 3 HEADLINER 2 ................................................................................................................ ................................................ Headliner Harness Connector 2 HEADLINER 1 ................................. ............................................................................................................................... Headliner Harness Connector 1 SEO/UPFITTER .......................................................................................................................... Special Equipment Option Upfitter Harness Connector CIRCUIT BREAKER - USAGE CB1 ......................................................................................................................................................... Passenger Side Power Window Circuit Breaker CB2 ......................................................................... .......................................................................................................... Passenger Seat Circuit Breaker CB3 ...................................................................................................................................................... .................................. Driver Seat Circuit Breaker CB4 ....................................................................... .......................................................................................................................... Rear Sliding Window Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 11260 Fuse: Locations Instrument Panel Fuse Block - Owners Manual INSTRUMENT PANEL FUSE BLOCK The instrument panel fuse block access door is located on the driver side edge of the instrument panel. Pull off the cover to access the fuse block. The vehicle may not use all of the fuses shown. FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. .............................................................. Rear Seats Fuse 2 ................................................................ .................................................................................................................. Rear Accessory Power Outlet Fuse 3 ....................................................................................................................................... ................................... Steering Wheel Controls Backlight Fuse 4 ...................................................... .......................................................................................................................................... Driver Door Module Fuse 5 ..................................................................................................................................... ............................... Dome Lamps, Driver Side Turn Signal Fuse 6 .................................................... ...................................................................................................................... Driver Side Turn Signal, Stoplamp Fuse 7 ................................................................................................................................. .............................................. Instrument Panel Back Lighting Fuse 8 ................................................ .................................................................................................................... Passenger Side Turn Signal, Stoplamp Fuse 9 ..................................................................................................................... ............................................. Passenger Door Module, Driver Unlock Fuse 10 .................................. ................................................................................................................................. Power Door Lock 2 (Unlock Feature) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 11261 Fuse 11 ................................................................................................................................................ ....................... Power Door Lock 2 (Lock Feature) Fuse 12 ......................................................................................................................................................... Stoplamps, Center-High Mounted Stoplamp Fuse 13 ......................................................................... .................................................................................................................. Rear Climate Controls Fuse 14 ................................................................................................................................................ ......................................................... Power Mirror Fuse 15 ................................................................ ............................................................................................................... Body Control Module (BCM) Fuse 16 ................................................................................................................................................ ....................................... Accessory Power Outlets Fuse 17 .............................................................. ......................................................................................................................................... Interior Lamps Fuse 18 .................................................................................................................................... ............................... Power Door Lock 1 (Unlock Feature) Fuse 19 .................................................... .................................................................................................................................... Rear Seat Entertainment Fuse 20 ..................................................................................................................................................... Ultrasonic Rear Parking Assist, Power Liftgate Fuse 21 ..................................................................... .................................................................................................. Power Door Lock 1 (Lock Feature) Fuse 22 ................................................................................................................................................ ........................... Driver Information Center (DIC) Fuse 23 ................................................................. ............................................................................................................................................ Rear Wiper Fuse 24 ..................................................................................................................................... ..................................................................... Cooled Seats Fuse 25 .............................................................................................................................................. Driver Seat Module, Remote Keyless Entry System Fuse 26 ........................................................................................................................................................... Driver Power Door Lock (Unlock Feature) CIRCUIT BREAKER ............................................................................................................................ ................................................................ USAGE LT DR .......................................................................................................................................................... Driver Side Power Window Circuit Breaker HARNESS CONNECTOR ................................................................................................................... ................................................................. USAGE LT DR .................................................................................................................................................. .......................... Driver Door Harness Connection BODY .................................................................. ................................................................................................................................ Harness Connector BODY ................................................................................................................................. ................................................................. Harness Connector Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 11262 Fuse: Locations Underhood Fuse Block - Owners Manual UNDERHOOD FUSE BLOCK The underhood fuse block is located in the engine compartment, on the driver side of the vehicle. Lift the cover to access the fuse block. Notice: Spilling liquid on any electrical components on the vehicle may damage it. Always keep the covers on any electrical component. To remove fuses, hold the end of the fuse between your thumb and index finger and pull straight out. FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. ............................... Right Trailer Stop/Turn Lamp Fuse 2 ......................................................................................................................... Electronic Suspension Control, Automatic Level Control Exhaust Fuse 3 ............................................................................... .................................................................................................... Left Trailer Stop/Turn Lamp Fuse 4 .............................................................................................................................................................. ......................................... Engine Controls Fuse 5 ............................................................................. .................................................................................. Engine Control Module, Throttle Control Fuse 6 ........................................................................................................................................................... ............................... Trailer Brake Controller Fuse 7 ........................................................................... ................................................................................................................................ Front Washer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 11263 Fuse 8 .................................................................................................................................................. ....................................................... Oxygen Sensor Fuse 9 ................................................................ ........................................................................................................................ Antilock Brakes System 2 Fuse 10 ................................................................................................................................ .......................................................... Trailer Back-up Lamps Fuse 11 ............................................... .......................................................................................................................... Driver Side Low-Beam Headlamp Fuse 12 ............................................................................................................ .............................................................. Engine Control Module (Battery) Fuse 13 ............................................................................................................................................................. Fuel Injectors, Ignition Coils (Right Side) Fuse 14 .............................................................................. .................................................................................. Transmission Control Module (Battery) Fuse 15 ......................................................................................................................................................... ................................ Vehicle Back-up Lamps Fuse 16 ........................................................................ ........................................................................................... Passenger Side Low-Beam Headlamp Fuse 17 ................................................................................................................................................ ................................ Air Conditioning Compressor Fuse 18 ................................................................ ..................................................................................................................................... Oxygen Sensors Fuse 19 ................................................................................................................................. .......................................... Transmission Controls (Ignition) Fuse 20 ................................................. ............................................................................................................................................................. Fuel Pump Fuse 21 ............................................................................................................................. .................................................... Fuel System Control Module Fuse 22 ............................................ .............................................................................................................................................................. ...... Not Used Fuse 23 ......................................................................................................................... ....................................................................................... Not Used Fuse 24 ........................................ ....................................................................................................................... Fuel Injectors, Ignition Coils (Left Side) Fuse 25 ..................................................................................................................... ........................................................................... Trailer Park Lamps Fuse 26 .................................... ..................................................................................................................................................... Driver Side Park Lamps Fuse 27 ......................................................................................................... .......................................................................... Passenger Side Park Lamps Fuse 28 ...................... .............................................................................................................................................................. ......................... Fog Lamps Fuse 29 ................................................................................................... .................................................................................................................... Horn Fuse 30 .................. ................................................................................................................................................. Passenger Side High-Beam Headlamp Fuse 31 ................................................................................. ........................................................................................... Daytime Running Lamps (DRL) Fuse 32 . .............................................................................................................................................................. ......... Driver Side High-Beam Headlamp Fuse 33 .............................................................................. ....................................................................................................... Daytime Running Lights 2 Fuse 34 ......................................................................................................................................................... ......................................................... Sunroof Fuse 35 ....................................................................................................................................................... Key Ignition System, Theft Deterrent System Fuse 36 ........................................................................ .......................................................................................................................... Windshield Wiper Fuse 37 ................................................................................................................................................ .......................... SEO B2 Upfitter Usage (Battery) Fuse 38 ................................................................ ..................................................................................................................... Electric Adjustable Pedals Fuse 39 .................................................................................................................................... ................................................. Climate Controls (Battery) Fuse 40 ................................................... .................................................................................................................................... Airbag System (Ignition) Fuse 41 ................................................................................................................................. .............................................................................. Amplifier Fuse 42 .................................................. ....................................................................................................................................................... Audio System Fuse 43 ........................................................................................................................ ....................................... Miscellaneous (Ignition), Cruise Control Fuse 44 ........................................ .............................................................................................................................................................. .......... Not Used Fuse 45 ..................................................................................................................... ................................................................... Airbag System (Battery) Fuse 46 .................................... .................................................................................................................................................... Instrument Panel Cluster Fuse 47 ....................................................................................................... .............................................................................................. Power Take-Off Fuse 48 ...................... ............................................................................................................................................... Auxiliary Climate Control (Ignition) Fuse 49 ........................................................................................................................................................... Center High-Mounted Stoplamp (CHMSL) Fuse 50 ............................................................................ ............................................................................................................................ Rear Defogger Fuse 51 ......................................................................................................................................................... .............................................. Heated Mirrors Fuse 52 ........................................................................ .................................................................................................. SEO B1 Upfitter Usage (Battery) Fuse 53 ............................................................................................................................................................. Cigarette Lighter, Auxiliary Power Outlet Fuse 54 ............................................................................... ................................................................................................................ SEO Upfitter Usage Fuse 55 ......................................................................................................................................................... ........................... Climate Controls (Ignition) Fuse 56 .................................................................................................................................... Engine Control Module, Secondary Fuel Pump (Ignition) J-CASE FUSES ................................................................................................................................... ................................................................... USAGE Fuse 57 ................................................................................................................................................ ........................................................ Cooling Fan 1 Fuse 58 ............................................................... ................................................................................................................................................. Not Used Fuse 59 ...................................................................................................................................... ................................ Heavy Duty Antilock Brake System Fuse 60 ...................................................... .................................................................................................................................................. Cooling Fan 2 Fuse 61 ........................................................................................................................ ............................................................... Antilock Brake System 1 Fuse 62 ........................................ .............................................................................................................................................................. .............. Starter Fuse 63 ..................................................................................................................... ..................................................................... Stud 2 (Trailer Brakes) Fuse 64 .................................... ......................................................................................................................................... Left Bussed Electrical Center 1 Fuse 65 ................................................................................................................. ............................................................................................... Not Used Fuse 66 ................................ ....................................................................................................................................... Heated Windshield Washer System Fuse 67 ................................................................................................... ...................................................................................................... Transfer Case Fuse 68 ........................................................................................................ Stud 1 (Trailer Connector Battery Power) (Optional - 40A Fuse Required) Fuse 69 .................................................. ........................................................................................................................... Mid-Bussed Electrical Center 1 Fuse 70 ................................................................................................................. ........................................................................ Climate Control Blower Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 11264 Fuse 71 ................................................................................................................................................ ................................................................ Not Used Fuse 72 ............................................................... .............................................................................................................. Left Bussed Electrical Center 2 RELAYS .............................................................................................................................................. .................................................................... USAGE FAN HI ................................................................................................................................................. ...................................... Cooling Fan High Speed FAN LO ................................................................ ....................................................................................................................... Cooling Fan Low Speed FAN CNTRL ............................................................................................................................. ........................................................ Cooling Fan Control HDLP LO/HID ............................................ .................................................................................................................................... Low-Beam Headlamp FOG LAMP ......................................................................................................................... ................................................................... Front Fog Lamps A/C CMPRSR ...................................... ............................................................................................................................... Air Conditioning Compressor STRTR ............................................................................................................................ ........................................................................................ Starter PWR/TRN ....................................... .............................................................................................................................................................. ... Powertrain FUEL PMP .................................................................................................................... ................................................................................... Fuel Pump PRK LAMP .................................... ............................................................................................................................................................ Parking Lamps REAR DEFOG ............................................................................................................ ............................................................................... Rear Defogger RUN/CRANK ............................... .......................................................................................................................................................... Switched Power Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood Fuse: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11267 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11268 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11269 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11270 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11271 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11272 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11273 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11274 Fuse Block - Underhood Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11275 Fuse Block - Underhood X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11276 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11277 Fuse Block - Underhood X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11278 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11279 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11280 Fuse Block - Underhood X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11281 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11282 Fuse Block - Underhood X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11283 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11284 Fuse Block - Underhood X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11285 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11286 Fuse Block - Underhood X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11287 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11288 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11289 Fuse: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11290 Fuse Block - I/P Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11291 Fuse Block - I/P Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11292 Fuse Block - I/P X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11293 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11294 Fuse Block - I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11295 Fuse Block - I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11296 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11297 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11298 Fuse: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11299 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11300 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11301 Fuse: Application and ID Fuse Holder Electrical Center Identification Views Fuse Block - Auxiliary, Fuse Holder (HP2) Fuse Block - Auxiliary, Fuse Holder (HP2) Fuse Holder X1 (Gas except 9L4) Fuse Holder X1 (Diesel or Gas with 9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11302 Fuse Holder X2 (Gas with TP2) Fuse Holder X2 (Diesel or Gas except LU3) Fuse Holder X2 (LU3) Fuse Holder X2 (Gas except LU3) Fuse Holder X2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11303 Fuse Holder X3 (9L4) Fuse Holder X3 (Diesel) Fuse Holder X4 (TP2) Fuse Holder X4 (Diesel) Fuse Holder X4 (Diesel with K76 or YF2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11304 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11305 Fuse: Application and ID Junction Block Electrical Center Identification Views Junction Block - Left I/P, Label Junction Block - Left I/P, Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11306 Junction Block - Left I/P, Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11307 Junction Block - Left I/P X1 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11308 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11309 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11310 Junction Block - Left I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11311 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11312 Junction Block - Left I/P X3 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11313 Junction Block - Left I/P X4 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11314 Junction Block - Left I/P X5 (SPO Alarm or SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11315 Junction Block - Left I/P X7 (JF4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11316 Junction Block - Left I/P X8 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11317 Junction Block - Left I/P X9 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11318 Junction Block - Left I/P X10 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11319 Junction Block - Left I/P X11 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11320 Junction Block - Left I/P X12 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11321 Junction Block - Left I/P X13 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11322 Junction Block - Left I/P X14 (5X7, 5Y0, 9L4, SPO DVD or SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11323 Junction Block - Right I/P, Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11324 Junction Block - Right I/P (Wire Entry) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11325 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11326 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11327 Junction Block - Right I/P X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11328 Junction Block - Right I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11329 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11330 Junction Block - Right I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11331 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11332 Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11333 Junction Block - Rear Lamps X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11334 Junction Block - Rear Lamps X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11335 Junction Block - Rear Lamps X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11340 Fuse Block - I/P Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11341 Fuse Block - I/P Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11342 Fuse Block - I/P X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11343 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11344 Fuse Block - I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11345 Fuse Block - I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11346 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11347 Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11348 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11349 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11350 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11351 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11352 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11353 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11354 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11355 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11356 Fuse Block - Underhood Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11357 Fuse Block - Underhood X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11358 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11359 Fuse Block - Underhood X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11360 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11361 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11362 Fuse Block - Underhood X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11363 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11364 Fuse Block - Underhood X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11365 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11366 Fuse Block - Underhood X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11367 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11368 Fuse Block - Underhood X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11369 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11370 Fuse Block - Underhood X8 (JL1) Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11371 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11372 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11373 Fuse Block: Connector Locations Harness Routing Views Chassis Harness Routing (Except LY6/LMM/HP2) 1 - X300 2 - X408 (UD7) 3 - G401 4 - J423 (except LU3) 5 - J331 6 - Fuse Block - Underhood X3 7 - X115 8 - X102 (JL1) 9 - J338 (except LU3/LMG) 10 - J300 11 - G300 Chassis Harness Routing (LY6/LMM except 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11374 1 - X300 2 - X408 (UD7) 3 - Trailer Connector (UY7) 4 - J411 (JL1) 5 - G401 6 - J331 7 - Fuse Block - Underhood X3 8 - X115 9 - X102 (JL1) 10 - J300 11 - G300 Chassis Harness - Front Engine Compartment (31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11375 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Driver Door Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11376 1 - Door Frame 2 - Fuse Block - I/P X4 3 - J502 (YE9 without AN3) 4 - X500 (YE9 without AN3/DL3) 5 - X502 (ASF without YE9 or with AN3) Engine Harness Routing - Left Side (4.3L) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11377 1 - Throttle Body 2 - G107 3 - Transmission 4 - X300 5 - X109 6 - X110 (NQG/NQH) 7 - Fuse Block - Underhood X2 Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11378 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11379 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) I/P Harness Routing - Engine Compartment (Except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11380 1 - G110 (XA7) 2 - J113 (NQH) 3 - Fuse Block - Underhood X5 4 - Fuse Block - Underhood X4 5 Left Front Fender 6 - X103 7 - X109 8 - X115 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11383 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11384 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11385 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11386 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11387 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11388 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11389 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11390 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11391 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11392 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11393 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11394 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11395 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11396 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11397 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11398 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11399 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11400 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11401 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11402 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11403 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11404 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11405 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11406 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11407 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11408 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11409 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11410 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11411 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11412 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11413 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11414 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11415 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11416 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11417 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11418 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11419 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11420 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11421 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11422 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11423 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11424 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11425 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11426 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11427 Fuse Block: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11428 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11429 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11430 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11431 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11432 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11433 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11434 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11435 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11436 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11437 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11438 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11439 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11440 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11441 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11442 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11443 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11444 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11445 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11446 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11447 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11448 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11449 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11450 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11451 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11452 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11453 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11454 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11455 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11456 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11457 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11458 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11459 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11460 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11461 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11462 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11463 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11464 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11465 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11466 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11467 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11468 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11469 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11470 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11471 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11472 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11473 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11474 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11475 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11476 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11477 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11478 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11479 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11480 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11481 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11482 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11483 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11484 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11485 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11486 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11487 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11488 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11489 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11490 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11491 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11492 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11493 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11494 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11495 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11496 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11497 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11498 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11499 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11500 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11501 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11502 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11503 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11504 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11505 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11506 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11507 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11508 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11509 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11510 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11511 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11512 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11513 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11514 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11515 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11516 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11517 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11518 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11519 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11520 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11521 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11522 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11523 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11524 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11525 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11526 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11527 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11528 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11529 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11530 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11531 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11532 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11533 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11534 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11535 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11536 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11537 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11538 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11539 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11540 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11541 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11542 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11543 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11544 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11545 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11546 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11547 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11548 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11549 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11550 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11551 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11552 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11553 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11554 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11555 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11556 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11557 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11558 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11559 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11560 Fuse Block: Connector Views Electrical Center Identification Views Junction Block - Left I/P, Label Junction Block - Left I/P, Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11561 Junction Block - Left I/P, Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11562 Junction Block - Left I/P X1 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11563 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11564 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11565 Junction Block - Left I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11566 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11567 Junction Block - Left I/P X3 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11568 Junction Block - Left I/P X4 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11569 Junction Block - Left I/P X5 (SPO Alarm or SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11570 Junction Block - Left I/P X7 (JF4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11571 Junction Block - Left I/P X8 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11572 Junction Block - Left I/P X9 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11573 Junction Block - Left I/P X10 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11574 Junction Block - Left I/P X11 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11575 Junction Block - Left I/P X12 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11576 Junction Block - Left I/P X13 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11577 Junction Block - Left I/P X14 (5X7, 5Y0, 9L4, SPO DVD or SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11578 Junction Block - Right I/P, Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11579 Junction Block - Right I/P (Wire Entry) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11580 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11581 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11582 Junction Block - Right I/P X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11583 Junction Block - Right I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11584 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11585 Junction Block - Right I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11586 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11587 Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11588 Junction Block - Rear Lamps X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11589 Junction Block - Rear Lamps X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11590 Junction Block - Rear Lamps X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures Fuse Block: Procedures Ground Repair Electrical Grounds Proper electrical system function relies on secure, positive, corrosion-free ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacements. In general, electrical ground connections are accomplished using one, or a combination of, three attachment methods: * Welded M6 stud and nut * Welded M6 nut and bolt * Welded M8 nut and bolt Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. Determine which attachment method is used, and carry out the appropriate repair. M6 Weld Stud Replacement 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 5. Select a replacement conductive M6 rivet stud. Refer to GM parts catalog for the correct part number and application. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new rivet stud. 16. Select a new, conductive M6 nut. Refer to GM parts catalog for the correct part number and application. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 17. Install the M6 nut and tighten to 8 Nm (71 lb in). 18. Check for proper system operation. M6 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a new, conductive self-threading M7 bolt may be used to secure the ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive, self-threading M7 bolt Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11593 threads. 5. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 6. Install the electrical ground terminal to the new, conductive M7 bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the M7 bolt and tighten to 9 Nm (80 lb in). 8. Check for proper system operation. M6 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a conductive M6 bolt and a conductive M6 nut may be used to secure the electrical ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 ) clearance behind the panel surface and 20 mm (0.79 ) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M6 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M6 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). Note: The repair area must be properly refinished to maintain positive electrical grounding. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a conductive M8 bolt and a conductive M8 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent to M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M8 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M8 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M8 nut and tighten to 22 Nm (16 lb ft). Note: The repair area must be properly refinished to maintain positive electrical grounding. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11594 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a conductive M6 rivet stud and a conductive M6 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new, conductive M6 rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new, conductive M6 rivet stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 16. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). 17. Check for proper system operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11595 Fuse Block: Removal and Replacement 175 Amp Mega Fuse Replacement (Diesel) 175 Amp Mega Fuse Replacement (Diesel) Removal Procedure 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the mega fuse cover (3). 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11596 5. Remove the auxiliary battery positive cable nut (1) from the mega fuse holder. 6. Remove the generator battery jumper cable to fuse nut (3). 7. Remove the generator battery jumper cable terminal (2) from the fuse stud. 8. Remove the auxiliary battery positive cable from the fuse studs. 9. Remove the upper mega fuse nut (1), if necessary. 10. Remove the appropriate mega fuse (2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11597 1. Install the appropriate mega fuse (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the upper mega fuse nut (1), if necessary. Tighten the nut to 15 Nm (11 lb ft). 3. Install the auxiliary battery positive cable to the fuse studs. 4. Install the generator battery jumper cable terminal (2) to the fuse stud. 5. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 9 Nm (80 lb in). 6. Install the auxiliary battery positive cable nut (1) to the mega fuse holder. Tighten the nut to 15 Nm (11 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11598 7. Install the starter solenoid cable terminal (2) to the fuse stud. 8. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 9. Install the mega fuse cover (3). 10. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 175 Amp Mega Fuse Replacement (Single Battery) 175 Amp Mega Fuse Replacement (Single Battery) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11599 175 Amp Mega Fuse Replacement (Auxiliary Battery) 175 Amp Mega Fuse Replacement (Auxiliary Battery) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11600 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11601 Instrument Panel Electrical Center or Junction Block Replacement - Left Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11602 Instrument Panel Electrical Center or Junction Block Replacement - Left Side Body Wiring Harness Junction Block Replacement Body Wiring Harness Junction Block Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11603 Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11604 Underhood Electrical Center or Junction Block Bracket Replacement Underhood Electrical Center or Junction Block Bracket Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11605 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 11610 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 11611 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 11612 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 11613 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 11614 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 11615 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 11624 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 11625 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power > Page 11630 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 11636 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 11637 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 11638 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 11639 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 11644 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 11645 Multiple Junction Connector: Locations Harness Routing Views Rear Bumper Harness Routing 1 - Rear Bumper 2 - J403 (UD7) 3 - J404 (UD7) 4 - Junction Block - Rear Lamps Connector 5 X408 (UD7) Brake Clutch Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 11646 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chassis Harness (31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 11647 1 - Trailer Brake Control Relay (JL1) 2 - J422 (JL1) 3 - Trailer Connector 4 - J331 (Diesel without NQZ/LY6) 5 - X300 (LY6) 6 - X300 (Diesel) 7 - J411 (JL1) 8 - Junction Block - Rear Lamps 9 G401 10 - J338 (JL1) 11 - G300 12 - J300 (LY6 without NQZ) Passenger Door Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 11648 1 - J604 (YE9 without AN3/DL3) 2 - Junction Block - Right I/P X3 3 - Door Frame 4 - X601 (ASF) 5 - X600 (YE9 without AN3/DL3) 6 - J603 (YE9 without AN3/DL3) I/P Harness Routing - Passenger Compartment (Except HP2) - 1 of 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 11649 1 - X201 2 - X205 3 - Junction Block - Right I/P 4 - X200 5 - X202 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name Multiple Junction Connector: Diagrams Connector End Views By Name Ai - Ba Component Connector End Views (continued) Air Temperature Actuator - Left (CJ2) Air Temperature Actuator - Right (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11652 Air Temperature Actuator (C67 or C42) Air Temperature Sensor - Inside (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11653 Air Temperature Sensor - Lower Left (CJ2) Air Temperature Sensor - Lower Right (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11654 Air Temperature Sensor - Upper Left (CJ2) Air Temperature Sensor - Upper Right (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11655 Ambient Air Temperature Sensor (CJ2 or C67) Ambient Light Sensor (C67, C42 or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11656 Ambient Light/Sunload Sensor (CJ2) Audio Amplifier X1 (UQA with Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11657 Audio Amplifier X1 (UQA without Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11658 Audio Amplifier X2 (UQA) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11659 Audio Amplifier X3 (UQA) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11660 Audio/Video Adapter (U42) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11661 Automatic Transmission Auxiliary Fluid Pump Control Module X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11662 Automatic Transmission Auxiliary Fluid Pump Control Module X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11663 Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11664 Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11665 Automatic Transmission Internal Mode Switch (MW7) Automatic Transmission Shift Lever (M30, MYC, MYD, M99 or MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11666 Automatic Transmission Shift Lock Control Solenoid Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11667 Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X2 (TP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11668 Auxiliary Battery Relay X3 (TP2) Auxiliary Battery Run Relay (TP2) Auxiliary Body Control Module (XBCM) X1 (EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11669 Auxiliary Body Control Module (XBCM) X2 (EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11670 Backup Alarm (8S3) Backup Lamp - Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11671 Backup Lamp - Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11672 Backup Lamp Switch (TZ0) Barometric Pressure (BARO) Sensor (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11673 Battery - Left (-) (Auxiliary Battery Negative Cable) (6A6) Battery - Left (-) (Auxiliary Battery Negative Cable) (TP2) Battery - Left (-) (Battery Negative Cable) (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11674 Battery - Left (+) (Auxiliary Battery Positive Cable) (TP2) Battery - Left (+) (Starter Cable) (6A6 or Diesel) Battery - Right (-) (Battery Negative Cable) (Gas) Battery - Right (-) (Starter Cable) (Diesel) Ba - Da Component Connector End Views (continued) Battery - Right (+) (Diesel or 9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11675 Battery - Right (+) (Gas without 9L4) Battery (+) (Battery Positive Cable) (HP2) Battery (+) (Battery Positive Cable) (HP2) Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11676 Battery Module 1 (HP2) Battery Module 21 (HP2) Battery Module 22 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11677 Battery Module 40 (HP2) Blower Motor Blower Motor Control Module X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11678 Blower Motor Control Module X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11679 Body Control Module (BCM) X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11680 Body Control Module (BCM) X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11681 Body Control Module (BCM) X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11682 Body Control Module (BCM) X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11683 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11684 Body Control Module (BCM) X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11685 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11686 Body Control Module (BCM) X6 Body Control Module (BCM) X7 (except MEX or A52) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11687 Brake Booster Vacuum Sensor (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11688 Brake Fluid Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11689 Brake Master Cylinder Piston Position Sensor (HP2) Brake Master Cylinder Pressure Sensor (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11690 Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11691 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11692 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11693 Cellular Telephone Microphone (UE1, UUL or UUK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11694 Center High Mounted Stop Lamp (CHMSL) X1 Center High Mounted Stop Lamp (CHMSL) X2 Center High Mounted Stop Lamp (CHMSL) X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11695 Center High Mounted Stop Lamp (CHMSL) X4 Central Sequential Fuel Injection (Central SFI) X1-X6 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11696 Central Sequential Fuel Injection (Central SFI) X7 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11697 Chime Module (UL5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11698 Clutch Pedal Position (CPP) Switch (TZ0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11699 Control Solenoid Valve Assembly X1 (MYC, MYD or M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11700 Control Solenoid Valve Assembly X2 (MYC, MYD or M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11701 Control Solenoid Valve Assembly X3 (MYC, MYD or M99) Crankshaft Position (CKP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11702 Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11703 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11704 Data Link Connector (DLC) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11705 Da - Dr Component Connector End Views (continued) Data Link Resistor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11706 Data Link Resistor 2 (HP2) Digital Radio Receiver (U2K) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11707 Digital Video Disc (DVD) Control Module X1 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11708 Digital Video Disc (DVD) Control Module X2 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11709 Digital Video Disc (DVD) Control Module X3 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11710 Digital Video Disc (DVD) Control Module X4 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11711 Digital Video Disc (DVD) Control Module X5 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11712 Digital Video Disc (DVD) Control Module X6 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11713 Digital Video Disc (DVD) Display - Driver Seat Headrest X1 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11714 Digital Video Disc (DVD) Display - Driver Seat Headrest X2 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11715 Digital Video Disc (DVD) Display - Passenger Seat Headrest X1 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11716 Digital Video Disc (DVD) Display - Passenger Seat Headrest X2 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11717 Dome/Reading Lamps - Front Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11718 Dome/Reading Lamps - Rear (Crew Cab or Extended Cab) Door Latch - Driver (AU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11719 Door Latch - Driver (except AU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11720 Door Latch - Left Rear (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11721 Door Latch - Passenger Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11722 Door Latch - Right Rear (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11723 Door Lock Switch - Driver (AU3 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11724 Door Lock Switch - Passenger (AU3 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11725 Door Lock/Window Switch - Driver X1 (AN3 or DL3) Door Lock/Window Switch - Driver X2 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11726 Door Lock/Window Switch - Driver X3 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11727 Door Lock/Window Switch - Driver X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11728 Door Lock/Window Switch - Driver X7 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11729 Door Lock/Window Switch - Passenger X1 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11730 Door Lock/Window Switch - Passenger X2 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11731 Door Lock/Window Switch - Passenger X3 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11732 Door Lock/Window Switch - Passenger X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11733 Door Lock/Window Switch - Passenger X7 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11734 Drive Motor Battery Cable Terminal Extension Cover (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11735 Drive Motor Battery Current Sensor (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11736 Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11737 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11738 Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11739 Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11740 Drive Motor Generator Battery Control Module X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11741 Drive Motor Generator Battery Control Module X3 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11742 Drive Motor Generator Battery Control Module X4 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11743 Drive Motor Generator Battery Control Module X5 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11744 Dr - En Component Connector End Views (continued) Drive Motor Generator Battery X1 (HP2) Drive Motor Generator Battery X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11745 Drive Motor Generator Power Inverter Module Cover (HP2) Drive Motor Generator Power Inverter Module X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11746 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11747 Drive Motor Generator Power Inverter Module X2 (HP2) Drive Motor Generator Power Inverter Module X3 (HP2) Drive Motor Generator Power Inverter Module X4 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11748 Drive Motor Generator Power Inverter Module X5 (HP2) Drive Motor Generator Power Inverter Module X6 (HP2) Drive Motor Generator Power Inverter Module X7 (HP2) Drive Motor Generator Power Inverter Module X8 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11749 Drive Motor Generator Power Inverter Module X9 (HP2) Drive Motor Generator Power Inverter Module X10 (HP2) Drive Motor Generator Power Inverter Module X11 (HP2) Drive Motor Generator Power Inverter Module X12 (HP2) Drive Motor Power Inverter Current Limit Relay X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11750 Drive Motor Power Inverter Current Limit Relay X2 (HP2) Driver Information Center (DIC) Switch (except MEX or 8S8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11751 Electronic Adjustable Pedal (EAP) Assembly (JF4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11752 Electronic Brake Control Module (EBCM) (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11753 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11754 Electronic Brake Control Module (EBCM) (JF3 or JF7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11755 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11756 Electronic Brake Control Module (EBCM) (JH6 or JH7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11757 Electronic Brake Control Module (EBCM) (JL4 except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11758 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11759 Electronic Brake Control Module (EBCM) (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11760 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11761 Electronic Compass Module (YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11762 Electronic Power Steering Motor Control Module X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11763 Electronic Power Steering Motor Control Module X3 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11764 Electronic Power Steering Motor Control Module X4 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11765 Emergency Vehicle Roof Lamp Relay (5Y0) Engine Control Module (ECM) X1 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11766 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11767 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11768 Engine Control Module (ECM) X1 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11769 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11770 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11771 Engine Control Module (ECM) X1 (LY2, LMG, LC9, LY5, LH6, L76 or L9H) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11772 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11773 Engine Control Module (ECM) X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11774 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11775 Engine Control Module (ECM) X1 (LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11776 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11777 Engine Control Module (ECM) X2 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11778 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11779 En - Fu Component Connector End Views (continued) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11780 Engine Control Module (ECM) X2 (LY2, LY6 or L9H with Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11781 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11782 Engine Control Module (ECM) X2 (LMG, LC9, LY5, LH6, L76 or L9H without Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11783 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11784 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11785 Engine Control Module (ECM) X2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11786 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11787 Engine Control Module (ECM) X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11788 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11789 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11790 Engine Control Module (ECM) X3 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11791 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11792 Engine Coolant Level Switch (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11793 Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11794 Engine Cooling Fan - Left (Gas except LY6) Engine Cooling Fan - Right (Gas except LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11795 Engine Cooling Fan Resistor - Left (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11796 Engine Cooling Fan Resistor - Right (HP2) Engine Oil Level (EOL) Switch (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11797 Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11798 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11799 Evaporative Emission (EVAP) Canister Purge Solenoid Valve (Gas) Evaporative Emission (EVAP) Canister Vent Solenoid Valve (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11800 Evaporator Temperature Sensor (except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11801 Exhaust Gas Recirculation (EGR) Temperature Sensor 1 (Diesel) Exhaust Gas Recirculation (EGR) Temperature Sensor 2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11802 Exhaust Gas Recirculation (EGR) Valve (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11803 Exhaust Pressure Differential Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11804 Exhaust Temperature Sensor 1 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11805 Exhaust Temperature Sensor 2 (Diesel) Fog Lamp - Left Front (T96) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11806 Fog Lamp - Right Front (T96) Front Drive Axle Actuator (NQF, NQG or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11807 Fuel Heater (Diesel) Fuel Injector 1 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11808 Fuel Injector 1 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11809 Fuel Injector 1 (LU3) Fuel Injector 2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11810 Fuel Injector 2 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11811 Fuel Injector 2 (LU3) Fuel Injector 3 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11812 Fuel Injector 3 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11813 Fuel Injector 3 (LU3) Fuel Injector 4 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11814 Fuel Injector 4 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11815 Fuel Injector 4 (LU3) Fuel Injector 5 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11816 Fu - He Component Connector End Views (continued) Fuel Injector 5 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11817 Fuel Injector 5 (LU3) Fuel Injector 6 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11818 Fuel Injector 6 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11819 Fuel Injector 6 (LU3) Fuel Injector 7 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11820 Fuel Injector 7 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11821 Fuel Injector 8 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11822 Fuel Injector 8 (Gas except LU3) Fuel Level Sensor - Primary (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11823 Fuel Level Sensor - Secondary (Diesel with 31 Series without NQZ) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11824 Fuel Pressure Regulator (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11825 Fuel Pressure Sensor (Gas except LU3 or LY6) Fuel Pump/Trailer Brake Control Module (Gas with JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11826 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11827 Fuel Pump (Diesel with 31 Series without NQZ) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11828 Fuel Pump and Sender Assembly - Front (Gas except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11829 Fuel Pump and Sender Assembly - Front (MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11830 Fuel Pump and Sender Assembly - Rear (LY6 except MEX and without NQZ) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11831 Fuel Pump and Sender Assembly - Rear (LY6 with MEX and without NQZ) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11832 Fuel Pump Flow Control Module (Gas except JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11833 Fuel Pump Relay - Secondary (LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11834 Fuel Rail Pressure (FRP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11835 Fuel Tank Pressure (FTP) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11836 Fuel Temperature Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11837 Garage Door Opener (GDO) (UG1) Generator - Auxiliary X1 (Diesel with K76 or YF2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11838 Generator - Auxiliary X2 (Diesel with K76 or YF2) Generator Battery Vent Fan (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11839 Generator Battery Vent Fan Relay (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11840 Generator Control Module Coolant Pump - Left (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11841 Generator Control Module Coolant Pump - Right (HP2) Generator Control Module Temperature Sensor (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11842 Generator X1 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11843 Generator X1 (Gas) Generator X2 (Diesel) Generator X2 (LU3) Generator X2 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11844 Glow Plug Control Module (GPCM) X1 (Diesel) Glow Plug Control Module (GPCM) X2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11845 Headlamp - Left High Beam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11846 Headlamp - Left Low Beam Headlamp - Right High Beam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11847 Headlamp - Right Low Beam Headlamp and Panel Dimmer Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11848 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11849 He - In Component Connector End Views (continued) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (Gas except LU3 and except ZW9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11850 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY6 or L96 with ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11851 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (Gas except LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11852 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (Gas except LU3 and except ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY6 or L96 with ZW9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11853 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11854 Heated Seat Control Module X1 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11855 Heated Seat Control Module X2 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11856 Heated Seat Control Module X3 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11857 Heated Seat Control Module X4 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11858 Heated Seat Element - Driver Back (AN3 without KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11859 Heated Seat Element - Driver Back (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11860 Heated Seat Element - Driver Cushion (AN3 without KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11861 Heated Seat Element - Driver Cushion (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11862 Heated Seat Element - Passenger Back (AN3 without KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11863 Heated Seat Element - Passenger Back (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11864 Heated Seat Element - Passenger Cushion (AN3 without KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11865 Heated Seat Element - Passenger Cushion (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11866 Heated Seat Switch - Driver (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11867 Heated Seat Switch - Passenger (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11868 Heated Steering Wheel (KA9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11869 Heater Coolant Pump (HP2) High Voltage Circuit Impact Detection Sensor (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11870 Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11871 Horn - Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11872 Horn - Right (Z71, YE9 or HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11873 HVAC Control Module X1 (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11874 HVAC Control Module X2 (C67, C42 or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11875 HVAC Control Module X2 (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11876 HVAC Control Module X3 (C67, C42, CJ2 or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11877 Ignition Coil 1 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11878 Ignition Coil 2 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11879 Ignition Coil 3 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11880 Ignition Coil 4 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11881 Ignition Coil 5 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11882 Ignition Coil 6 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11883 Ignition Coil 7 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11884 Ignition Coil 8 (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11885 Ignition Control Module (ICM) (LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11886 Ignition Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11887 Inflatable Restraint Front End Sensor - Left (10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11888 Inflatable Restraint Front End Sensor - Right (10 Series) Inflatable Restraint Front End Sensor (except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11889 Inflatable Restraint I/P Module (10 Series except MEX) Inflatable Restraint I/P Module (20/30/31 Series or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11890 Inflatable Restraint I/P Module Disable Switch (C99 or MEX) Inflatable Restraint I/P Module Indicator (AL0 or C99 except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11891 Inflatable Restraint Passenger Presence System (PPS) Module (AL0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11892 Inflatable Restraint Roof Rail Module - Driver (Crew Cab with ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11893 Inflatable Restraint Roof Rail Module - Driver (Extended Cab with ASF) In - Ob Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11894 Component Connector End Views (continued) Inflatable Restraint Roof Rail Module - Driver (Regular Cab with ASF) Inflatable Restraint Roof Rail Module - Passenger (Crew Cab with ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11895 Inflatable Restraint Roof Rail Module - Passenger (Extended Cab with ASF) Inflatable Restraint Roof Rail Module - Passenger (Regular Cab with ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11896 Inflatable Restraint Seat Position Sensor - Driver (10 Series except MEX) Inflatable Restraint Seat Position Sensor - Passenger (10 Series except Crew Cab or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11897 Inflatable Restraint Sensing and Diagnostic Module (SDM) X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11898 Inflatable Restraint Sensing and Diagnostic Module (SDM) X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11899 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11900 Inflatable Restraint Side Impact Module - Left (10 Series except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11901 Inflatable Restraint Side Impact Module - Left (HP2) Inflatable Restraint Side Impact Module - Right (10 Series except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11902 Inflatable Restraint Side Impact Module - Right (HP2) Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11903 Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended or Crew Cab with ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11904 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended or Crew Cab with ASF) Inflatable Restraint Steering Wheel Module Coil X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11905 Inflatable Restraint Steering Wheel Module Coil X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11906 Inflatable Restraint Steering Wheel Module X1 (10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11907 Inflatable Restraint Steering Wheel Module X2 (10 Series) Inflatable Restraint Steering Wheel Module (except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11908 Infrared Transmitter (U42) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11909 Inside Rearview Mirror (ISRVM) (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11910 Instrument Panel Cluster (IPC) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11911 Intake Air Heater (IAH) X1 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11912 Intake Air Heater X2 (Diesel) Intake Air Temperature (IAT) Sensor 2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11913 Intake Air Valve (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11914 Knock Sensor (KS) 1 (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11915 Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11916 License Lamp - Left License Lamp - Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11917 Manifold Absolute Pressure (MAP) Sensor (LU3) Manifold Absolute Pressure (MAP) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11918 Manifold Absolute Pressure (MAP) Sensor (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11919 Marker Lamp - Tailgate (RO5) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11920 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11921 Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11922 Memory Seat Module (MSM) X3 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11923 Memory Seat Module (MSM) X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11924 Memory Seat Module (MSM) X5 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11925 Memory Seat Module (MSM) X6 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11926 Memory Seat Module (MSM) X7 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11927 Mode Actuator (C67, C42 or CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11928 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Multifunction Switch - I/P (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11929 Noise Compensation Microphone (UQA with Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11930 Object Alarm Sensor - Left Rear Corner (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11931 Ob - Se Component Connector End Views (continued) Object Alarm Sensor - Left Rear Middle (UD7) Object Alarm Sensor - Right Rear Corner (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11932 Object Alarm Sensor - Right Rear Middle (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11933 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11934 Outside Rearview Mirror - Driver (DL3, DL8 or DPN) Outside Rearview Mirror - Passenger (DL3, DL8 or DPN) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11935 Outside Rearview Mirror Switch (DL8 or DPN) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11936 Park Brake Switch Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11937 Park/Turn Signal Lamp - Lower Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11938 Park/Turn Signal Lamp - Lower Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11939 Park/Turn Signal Lamp - Upper Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11940 Park/Turn Signal Lamp - Upper Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11941 Power Steering Assist Motor X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11942 Power Steering Assist Motor X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11943 Power Take Off (PTO) Module (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11944 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11945 Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11946 Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11947 Pressure Control (PC) Solenoid Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11948 Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11949 Pressure Switch Manifold (PSM) (MW7) Radio X1 (except Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11950 Radio X1 (Y91 or 8S8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11951 Radio X2 (except Y91 or 8S8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11952 Radio X2 (Y91 or 8S8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11953 Radio X3 (U42) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11954 Radio X4 (UUL or UUK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11955 Rear Fender Clearance Lamp - Left Front (RO5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11956 Rear Fender Clearance Lamp - Left Rear (RO5) Rear Fender Clearance Lamp - Right Front (RO5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11957 Rear Fender Clearance Lamp - Right Rear (RO5) Rear Object Sensor Control Module X1 (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11958 Rear Object Sensor Control Module X2 (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11959 Rear Seat Audio (RSA) Control X1 (UK6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11960 Rear Seat Audio (RSA) Control X2 (UK6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11961 Rear Window Defogger Grid X1 (C49) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11962 Rear Window Defogger Grid X2 (C49) Rearview Camera (SPO Rearview Camera) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11963 Rearview Camera Image Display Module X1 (UVC) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11964 Rearview Camera Image Display Module X2 (UVC) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11965 Recirculation Actuator (C67 or CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11966 Remote Control Door Lock Receiver (RCDLR) (AP3 or AP8) Roof Beacon Relay (TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11967 Roof Beacon Switch (5X7, 5Y0 or TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11968 Roof Clearance Lamp - Left Front Outer (U01) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11969 Roof Clearance Lamp - Front Middle (U01) Roof Clearance Lamp - Right Front Outer (U01) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11970 Seat Adjuster Motor Assembly - Driver (AG1 without AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11971 Seat Adjuster Motor Assembly - Driver X1 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11972 Se - Sp Component Connector End Views (continued) Seat Adjuster Motor Assembly - Driver X2 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11973 Seat Adjuster Motor Assembly - Passenger (AG2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11974 Seat Adjuster Switch - Driver (AG1 without AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11975 Seat Adjuster Switch - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11976 Seat Adjuster Switch - Passenger (AG2 without AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11977 Seat Adjuster Switch - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11978 Seat Back Ventilation Heating and Cooling Module - Driver (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11979 Seat Back Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11980 Seat Belt Buckle - Driver Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11981 Seat Belt Buckle - Passenger X1 (10 Series without MEX) Seat Belt Buckle - Passenger X2 (AL0) Seat Belt Pretensioner - Driver Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11982 Seat Belt Pretensioner - Passenger Seat Climate Control Module X1 (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11983 Seat Climate Control Module X2 (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11984 Seat Climate Control Module X3 (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11985 Seat Cushion Ventilation Heating and Cooling Module - Driver (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11986 Seat Cushion Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11987 Seat Front Vertical Motor - Driver (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11988 Seat Front Vertical Motor - Passenger (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11989 Seat Horizontal Motor - Driver (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11990 Seat Horizontal Motor - Passenger (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11991 Seat Lumbar Horizontal Motor - Driver (AN3) Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11992 Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) Seat Lumbar Switch - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11993 Seat Lumbar Switch - Passenger (AN3) Seat Lumbar Vertical Motor - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11994 Seat Lumbar Vertical Motor - Passenger (AN3) Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11995 Seat Rear Vertical Motor - Driver (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11996 Seat Rear Vertical Motor - Passenger (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11997 Seat Recline Motor - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11998 Seat Recline Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11999 Seat Recline Position Sensor - Driver (AN3) Security Indicator Lamp (SPO Alarm) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12000 Serial Data Gateway (SDG) Module X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12001 Serial Data Gateway (SDG) Module X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12002 Shift Solenoid (SS) Valve 1 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12003 Shift Solenoid (SS) Valve 2 (MW7) Shift Solenoid (SS) Valve 3 (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12004 Side Marker Lamp - Left Front (Z88) Side Marker Lamp - Left Rear (Z88) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12005 Side Marker Lamp - Right Front (Z88) Side Marker Lamp - Right Rear (Z88) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12006 Sliding Rear Window Close Relay (A48) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12007 Sliding Rear Window Motor (A48) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12008 Sliding Rear Window Open Relay (A48) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12009 Sliding Rear Window Switch (A48) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12010 Speaker - Center I/P (UQA with Y91) Speaker - Left Front (UQ3) Speaker - Left Front (UQ5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12011 Speaker - Left Front (UQA) Sp - Tr Component Connector End Views (continued) Speaker - Left Front Tweeter (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12012 Speaker - Left Rear (Extended Cab or Crew Cab with UQ3 or UQ5) Speaker - Left Rear (Extended Cab or Crew Cab with UQA) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12013 Speaker - Left Rear (Regular Cab) Speaker - Right Front (UQ3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12014 Speaker - Right Front (UQ5) Speaker - Right Front (UQA) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12015 Speaker - Right Front Tweeter (except MEX) Speaker - Right Rear (Extended Cab or Crew Cab with UQ3 or UQ5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12016 Speaker - Right Rear (Extended Cab or Crew Cab with UQA) Speaker - Right Rear (Regular Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12017 Speaker - Subwoofer (UQA) Starter Motor X1 (5X7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12018 Starter Motor X1 (LU3 without 9L4) Starter Motor X1 (6A6) Starter Motor X1 (9L4 or Gas except LU3) Starter Motor X1 (Diesel) Starter Motor X2 (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12019 Starter Motor X2 (Gas) Steering Angle Sensor (JL4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12020 Steering Wheel Control Switch - Left (K34 or KA9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12021 Steering Wheel Control Switch - Right (UK3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12022 Stop Lamp Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12023 Sunroof Control Module (CF5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12024 Sunroof Switch (CF5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12025 Sunshade - Left (DH6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12026 Sunshade - Right (DH6) Tail/Stop and Turn Signal Lamp - Lower Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12027 Tail/Stop and Turn Signal Lamp - Lower Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12028 Tail/Stop and Turn Signal Lamp - Upper Left Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12029 Tail/Stop and Turn Signal Lamp - Upper Right Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12030 Theft Deterrent Module (TDM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12031 Throttle Body (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12032 Throttle Body (Gas except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12033 Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12034 Torque Converter Clutch (TCC) Solenoid Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12035 Wiring Diagram Trailer Brake Control Module (JL1 except 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12036 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12037 Trailer Brake Control Module (JL1 with 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12038 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12039 Trailer Brake Control Relay (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12040 Trailer Brake Control Switch (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12041 Trailer Connector (except MEX or EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12042 Trailer Stop/Turn Relay (TZ0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12043 Tr - Ya Component Connector End Views (continued) Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12044 Transfer Case Encoder Motor (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12045 Transfer Case Shift Control Module X1 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12046 Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12047 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12048 Transfer Case Shift Control Switch (NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12049 Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12050 Transmission Control Module (TCM) (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12051 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12052 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12053 Transmission Power Inverter Module (3 Phase) Cable Cover (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12054 Turbocharger Vane Position Control Solenoid Valve (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12055 Turbocharger Vane Position Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12056 Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Turn Signal/Multifunction Switch X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12057 Valve Lifter Oil Manifold (VLOM) Assembly (LMG, LC9, LZ1 or L96) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12058 Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12059 Vehicle Communication Interface Module (VCIM) X3 (UE1 with UUL or UUK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12060 Vehicle Inclination Sensor (SPO Alarm) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12061 Vehicle Shock Sensor (SPO Alarm) Vehicle Speed Sensor (VSS) (M30, TZ0, MYC and MW7or M99 with NQG or NQF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12062 Vehicle Speed Sensor (VSS) (MW7 except NQG or NQF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12063 Video Display (U42) Water in Fuel Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12064 Wheel Speed Sensor (WSS) - Left Front (10 Series) Wheel Speed Sensor (WSS) - Left Front (except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12065 Wheel Speed Sensor (WSS) - Left Rear (JL4 or HP2) Wheel Speed Sensor (WSS) - Right Front (10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12066 Wheel Speed Sensor (WSS) - Right Front (except 10 Series) Wheel Speed Sensor (WSS) - Right Rear (JL4 or HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12067 Window Motor - Driver (A31) Window Motor - Left Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12068 Window Motor - Passenger (A31) Window Motor - Right Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12069 Window Switch - Driver X1 (A31 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12070 Window Switch - Driver X2 (A31 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12071 Window Switch - Left Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12072 Window Switch - Passenger (A31 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12073 Window Switch - Right Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12074 Windshield Outside Moisture Sensor (CE1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12075 Windshield Washer Fluid Level Switch Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12076 Windshield Washer Fluid Pump Windshield Wiper Motor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12077 Wrecker Relay X1 (5X7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12078 Wrecker Relay X2 (5X7) Yaw and Lateral Accelerometer Sensor (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12079 Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12080 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12081 1-2 Shift - Ac Component Connector End Views 1-2 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12082 2-3 Shift Solenoid (SS) Valve (M30) A/C Compressor Clutch (C67) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12083 A/C Compressor Clutch (CJ2) A/C Compressor X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12084 A/C Compressor X2 (+) (HP2) A/C Compressor X3 (-) (HP2) A/C Low Pressure Sensor (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12085 A/C Refrigerant Pressure Sensor (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12086 A/C Refrigerant Pressure Sensor (Gas except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12087 A/C Refrigerant Pressure Sensor (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12088 Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12089 Accessory DC Power Control Module X1 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12090 Accessory DC Power Control Module X2 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12091 Accessory DC Power Control Module X3 (HP2) Accessory DC Power Control Module X4 (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12092 Accessory Power Outlet - Center Console (D07) Accessory Power Outlet - Center Console Compartment (D07) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12093 Accessory Power Outlet - Center Seat (AZ3) Accessory Power Outlet - I/P 1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12094 Accessory Power Outlet - I/P 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12095 Multiple Junction Connector: Diagrams Connector End Views By Number X100 Inline Harness Connector End Views X100 Forward Lamp Harness to Left Front Headlamp Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12096 X102 Inline Harness Connector End Views X102 Brake Clutch Harness to Chassis Harness (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12097 X103 Inline Harness Connector End Views X103 Instrument Panel Harness to Forward Lamp Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12098 X106 Inline Harness Connector End Views X106 Forward Lamp Harness to Right Front Headlamp Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12099 X107 Inline Harness Connector End Views X107 Engine Chassis Harness to Engine Harness (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12100 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12101 X108 Inline Harness Connector End Views X108 Engine Chassis Harness to Engine Harness (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12102 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12103 X109 Inline Harness Connector End Views X109 Engine Harness (LU3) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (LU3 or Diesel without NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12104 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12105 X109 Engine Harness (except Diesel) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (HP2, LU3 or Diesel with NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12106 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12107 X109 Engine Harness to Instrument Panel Harness (Gas except LU3 and without NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12108 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12109 X109 Engine Harness to Instrument Panel Harness (Gas except LU3 and with NQF or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12110 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12111 X110 Inline Harness Connector End Views X110 Engine Harness (except Diesel) or Engine Chassis Harness (Diesel) to Front Axle Harness (NQF, NQG or NQH) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12112 X111 Inline Harness Connector End Views X111 Engine Harness to Left Ignition Coil Harness (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12113 X112 Inline Harness Connector End Views X112 Engine Harness to Camshaft Position Sensor Jumper Harness (L20, LMG or LC9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12114 X112 Engine Harness to Camshaft Position Sensor Jumper Harness (LU3) X112 Engine Harness to Camshaft Position Sensor Jumper Harness (LZ1, LY6, L96 or L9H) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12115 X113 Inline Harness Connector End Views X113 Engine Harness to Right Ignition Coil Harness (Gas except LU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12116 X113 Engine Jumper Harness to Engine Harness (Diesel) X115 Inline Harness Connector End Views X115 Chassis Harness to Instrument Panel Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12117 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12118 X116 Inline Harness Connector End Views X116 Battery Positive Harness to Brake Clutch Harness (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12119 X117 Inline Harness Connector End Views X117 Fuel Rail Pressure Sensor Jumper Harness to Engine Harness (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12120 X120 Inline Harness Connector End Views X120 Engine Harness to Forward Lamp Harness (HP2) X121 Inline Harness Connector End Views X121 Battery Negative Harness to Battery Positive Harness (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12121 X124 Inline Harness Connector End Views X124 Engine Chassis Harness to PTO Jumper Harness (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12122 X125 Inline Harness Connector End Views X125 Heated Oxygen Sensor (HO2S) Jumper Harness to Engine Harness (LY6 with 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12123 X127 Inline Harness Connector End Views X127 Engine Chassis Harness to Generator Jumper Harness (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12124 X128 Inline Harness Connector End Views X128 Fuel Pressure Regulator Harness to Engine Harness (Diesel) X129 Inline Harness Connector End Views X129 Instrument Panel Harness to Chassis Harness (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12125 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12126 X131 Inline Harness Connector End Views X131 Chassis Harness to Engine Harness (LU3) X131 Chassis Harness to Engine Harness (L20, LMG, LC9 or L9H) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12127 X150 Inline Harness Connector End Views X150 Engine Harness to Instrument Panel Harness (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12128 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12129 X122 Inline Harness Connector End Views X122 Auxiliary Battery Harness to Engine Harness (TP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12130 X123 Inline Harness Connector End Views X123 Engine Chassis Harness to Instrument Panel Harness (PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12131 X175 Inline Harness Connector End Views X175 Engine Chassis Harness to Transmission Internal Harness (MW7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12132 X175 Engine Harness to Transmission Internal Harness (M30) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12133 X176 Inline Harness Connector End Views X176 Engine Harness to Transmission Harness (M99) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12134 X200 Inline Harness Connector End Views X200 Instrument Panel Harness to Body Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12135 X201 Inline Harness Connector End Views X201 Steering Column Harness to Instrument Panel Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12136 X202 Inline Harness Connector End Views X202 Instrument Panel Harness to Body Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12137 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12138 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12139 X203 Inline Harness Connector End Views X203 Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) to Headliner Harness (UE1, UUL or UUK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12140 X204 Inline Harness Connector End Views X204 Headliner Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) (U42) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12141 X205 Inline Harness Connector End Views X205 Brake Clutch Harness to Instrument Panel Harness (except TZ0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12142 X205 Brake Clutch Harness to Instrument Panel Harness (TZ0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12143 X206 Inline Harness Connector End Views X206 Right A-Pillar Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) (U42) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12144 X207 Inline Harness Connector End Views X207 Instrument Panel Harness to Instrument Panel Harness (6J4) X208 Inline Harness Connector End Views X208 Body Harness to Headliner Harness (YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12145 X209 Inline Harness Connector End Views X209 Rearview Camera Chassis Harness to Rearview Camera I/P Jumper Harness (SPO Rearview Camera) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12146 X210 Inline Harness Connector End Views X210 Rearview Camera I/P Jumper Harness to Rearview Camera I/P Jumper Extension Harness (SPO Rearview Camera with KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12147 X212 Inline Harness Connector End Views X212 Instrument Panel Harness to I/P Extension Harness (except Y91, MEX or 8S8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12148 X214 Inline Harness Connector End Views X214 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) X215 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12149 Inline Harness Connector End Views X215 Body Harness to Instrument Panel Harness (HP2) X219 Inline Harness Connector End Views X219 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12150 X224 Inline Harness Connector End Views X224 Brake Clutch Harness to Beacon Harness (5Y0 or 5X7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12151 X225 Inline Harness Connector End Views X225 Brake Clutch Harness to Battery Positive Harness (9L4) X226 Inline Harness Connector End Views X226 Fuse Block Jumper Harness to Brake Clutch Harness (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12152 X227 Inline Harness Connector End Views X227 LED Indicator Harness to SPO Theft Harness (SPO Alarm) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12153 X228 Inline Harness Connector End Views X228 Beacon Harness to Chassis Harness (5Y0) X240 Inline Harness Connector End Views X240 I/P Extension Harness to Instrument Panel Harness (UVC except Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12154 X241 Inline Harness Connector End Views X241 Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) to Body Harness (UVC with DRC or DD8) X275 Inline Harness Connector End Views X275 Inflatable Restraint Steering Wheel Module Coil to Body Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12155 X276 Inline Harness Connector End Views X276 Inflatable Restraint Steering Wheel Module Coil to Steering Column Harness (KA9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12156 X277 Inline Harness Connector End Views X277 Inflatable Restraint Steering Wheel Module Coil to Heated Steering Wheel Harness (KA9) X278 Inline Harness Connector End Views X278 Instrument Panel Harness to Body Harness (MEX or A52) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12157 X279 Inline Harness Connector End Views X279 Instrument Panel Harness to Headliner Harness (MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12158 X300 Inline Harness Connector End Views X300 Chassis Harness to Engine Chassis Harness (Diesel) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12159 X300 Engine Harness to Chassis Harness (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12160 X300 Chassis Harness to Engine Harness (LY6 or L96) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12161 X301 Inline Harness Connector End Views X301 Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) to Console Harness (Y91, UQA or D07) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12162 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12163 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12164 X303 Inline Harness Connector End Views X303 Body Harness to Driver Seat Harness (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12165 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12166 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12167 X303 Body Harness to Driver Seat Harness (except AN3 or MEX) X303 Driver Seat Harness to Body Harness (MEX or A52) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12168 X304 Inline Harness Connector End Views X304 Headliner Harness to Overhead Console Harness (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12169 X305 Inline Harness Connector End Views X305 Body Harness to Passenger Seat Harness (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12170 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12171 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12172 X305 Body Harness to Passenger Seat Harness (except AN3 or MEX) X306 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12173 Inline Harness Connector End Views X306 Headliner Harness to Right A-Pillar Harness (U42) X309 Inline Harness Connector End Views X309 Body Harness to Console Harness (Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12174 X313 Inline Harness Connector End Views X313 Sunroof Harness (CF5) or Overhead Console Harness (TRW, 5X7 or 5Y0) to Right A-Pillar Harness (CF5, TRW, 5X7 or 5Y0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12175 X318 Inline Harness Connector End Views X318 Headliner Harness to CHMSL Harness Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12176 X319 Inline Harness Connector End Views X319 Body Harness to Console Harness (HP2, AZ3 or D07 with UQ3) X320 Inline Harness Connector End Views X320 Body Harness to Sliding Rear Window Jumper Harness (A48) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12177 X324 Inline Harness Connector End Views X324 Driver Seat Harness to Driver Seat Jumper Harness (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12178 X325 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12179 Inline Harness Connector End Views X325 Passenger Seat Harness to Passenger Seat Jumper Harness (AN3) X330 Inline Harness Connector End Views X330 Heated Seat Body Harness to Heated Driver Seat Harness (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12180 X331 Inline Harness Connector End Views X331 Heated Seat Body Harness to Heated Driver Seat Harness (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12181 X332 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12182 Inline Harness Connector End Views X332 Heated Passenger Seat Harness to Heated Seat Body Harness (SPO Heated Seats) X333 Inline Harness Connector End Views X333 Heated Seat Body Harness to Heated Seat Body Harness (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12183 X334 Inline Harness Connector End Views X334 Heated Seat Body Harness to Heated Seat Body Harness (SPO Heated Seats) X350 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12184 Inline Harness Connector End Views X350 Body Harness to Drive Motor Generator Battery Control Harness (HP2) X371 Inline Harness Connector End Views X371 SPO Accessory Signal Cable 1A to SPO Accessory Signal Cable 3A (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12185 X372 Inline Harness Connector End Views X372 SPO Accessory Signal Cable 2B to SPO Accessory Signal Cable 3B (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12186 X373 Inline Harness Connector End Views X373 SPO Accessory Signal Cable 2A to SPO Accessory Signal Cable 3A (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12187 X374 Inline Harness Connector End Views X374 SPO Accessory Signal Cable 1B to SPO Accessory Signal Cable 3B (SPO DVD) X414 Inline Harness Connector End Views X414 Chassis Harness to Camper Harness (UY2 or 8S3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12188 X415 Inline Harness Connector End Views X415 Rear Bumper Harness to Left Hip Lamp Harness (RO5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12189 X451 Inline Harness Connector End Views X451 Body Ground Jumper Harness to Rear Axle Ground Jumper Harness (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12190 X408 Inline Harness Connector End Views X408 Chassis Harness to Rear Bumper Harness (UD7) X416 Inline Harness Connector End Views X416 Rear Bumper Harness to Right Hip Lamp Harness (RO5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12191 X500 Inline Harness Connector End Views X500 Left Front Door Harness to Body Harness (YE9 or HP2, without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12192 X501 Inline Harness Connector End Views X501 Left Front Door Harness to Body Harness (YE9 or HP2, without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12193 X502 Inline Harness Connector End Views X502 Left Front Door Harness to Body Harness (ASF with AN3 or DL3, and except YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12194 X600 Inline Harness Connector End Views X600 Right Front Door Harness to Body Harness (YE9 or HP2, without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12195 X601 Inline Harness Connector End Views X601 Right Front Door Harness to Body Harness (ASF) X700 - X799 Inline Harness Connector End Views X700 Body Harness to Left Rear Door Harness (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12196 X700 Left Rear Door Harness to Body Harness (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12197 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12198 X800 - X899 Inline Harness Connector End Views X800 Body Harness to Right Rear Door Harness (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12199 X800 Right Rear Door Harness to Body Harness (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12200 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12201 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 12206 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 12207 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 12213 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 12214 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12219 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12220 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12221 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12222 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12223 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12224 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12225 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12226 Fuse Block - Underhood Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12227 Fuse Block - Underhood X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12228 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12229 Fuse Block - Underhood X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12230 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12231 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12232 Fuse Block - Underhood X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12233 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12234 Fuse Block - Underhood X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12235 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12236 Fuse Block - Underhood X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12237 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12238 Fuse Block - Underhood X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12239 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12240 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12241 Relay Box: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12242 Fuse Block - I/P Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12243 Fuse Block - I/P Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12244 Fuse Block - I/P X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12245 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12246 Fuse Block - I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12247 Fuse Block - I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12248 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12249 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12250 Relay Box: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12251 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12252 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12257 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12258 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12259 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12260 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12261 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12262 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12263 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12264 Fuse Block - Underhood Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12265 Fuse Block - Underhood X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12266 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12267 Fuse Block - Underhood X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12268 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12269 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12270 Fuse Block - Underhood X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12271 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12272 Fuse Block - Underhood X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12273 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12274 Fuse Block - Underhood X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12275 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12276 Fuse Block - Underhood X6 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12277 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12278 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12279 Relay Box: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12280 Fuse Block - I/P Top View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12281 Fuse Block - I/P Bottom View Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12282 Fuse Block - I/P X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12283 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12284 Fuse Block - I/P X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12285 Fuse Block - I/P X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12286 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12287 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12288 Relay Box: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12289 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12290 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 10157 > May > 10 > Campaign - Engine Harness Connection Not Latched Wiring Harness: Recalls Campaign - Engine Harness Connection Not Latched SERVICE UPDATE Bulletin No.: 10157 Date: May 24, 2010 Subject: 10157 - Service Update for Inventory and Customer Vehicles - Chassis-to-Engine Harness Connection Not Latched - Expires with Base Warranty Models: 2010 Chevrolet Silverado 2010 GMC Sierra 1500 Series This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to inspect the connection of the chassis-to-engine wire harness connection. If the chassis 12-way connector is not fully seated, connected and latched to the mating engine harness connector, it could create an electrical issue that would be difficult for technicians to diagnose. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers using WINS) or the Investigate Vehicle History link (dealers using GWM). Not all vehicles within the above breakpoints may be involved. Parts Information No parts are required for this update. Service Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 10157 > May > 10 > Campaign - Engine Harness Connection Not Latched > Page 12299 1. Locate the chassis 12-way connector (1). The connector is located on the top of the driver's side shock tower. Refer to illustration. 2. Determine if the chassis 12-way connector is fully seated, connected and latched to the mating engine harness connector. - If the 12-way connector is properly connected, no further action is required. - If the 12-way connector is NOT properly connected, proceed to Step 3. 3. Carefully remove the 12-way connector from the shock tower. 4. Seat the 12-way connector face (2) as shown in illustration. 5. Reconnect the 12-way connector. Ensure that the connector is fully seated, connected and latched to the mating engine harness connector. 6. Re-install the 12-way connector on the shock tower. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's Wiring Harness: Customer Interest Restraint System - Air Bag Warning Lamp On Repeat DTC's TECHNICAL Bulletin No.: 11-09-41-002 Date: March 17, 2011 Subject: Air Bag Warning Lamp Illuminated, Repeat History DTC B0083 0F - B0088 0F (Follow SI and Procedure Outlined Below if necessary) Models: 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT, Escalade Hybrid 2010-2011 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2010-2011 GMC Sierra, Sierra Denali, Sierra Hybrid, Yukon, Yukon XL, Yukon XL Denali, Yukon Hybrid, Yukon Denali Hybrid Condition In extremely rare cases, some customers may comment that the air bag warning lamp is illuminated. This condition may be intermittent and when checking the vehicle for DTCs, the SDM may report B0083, B0084, B0085, B0086, B0087 and/or B0088 with symptom code 0F. The code will be stored in history and may be repeated. The code probably will not be current. Cause This condition may be caused by possible electro-magnetic interference (EMI) in the Amarillo, Texas area from external sources such as aviation airspace traffic radar, creating erratic sensor information to the SDM. Correction Perform all diagnostics and repairs documented in SI. Notice If published SI repair information does not resolve the condition, perform the procedure below. Install a steward clamp ferrite bead following the procedure below: 1. Disconnect battery. Refer to SIR Disabling and Enabling in SI. 2. Remove the door trim. Refer to SI door trim removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's > Page 12305 3. Install the steward clamp ferrite bead on the wire harness (1). 4. Place tape around the steward clamp ferrite bead (1) to avoid vibration or movement. Verify that the door glass does not come in contact with it. 5. Reinstall the door trim. Refer to SI door trim removal. 6. Reconnect the battery. Refer to SIR Disabling and Enabling in SI. Parts Information Parts (Laird HFA100049-0A2) can be purchased from Digi-Key Corporation at www.digikey.com. Material allowance for repair is $1.10 each (in Canada, $1.21). Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative > Page 12310 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12315 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12316 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12317 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12318 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12323 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12324 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12325 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 12330 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative > Page 12335 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-45-002A > May > 10 > Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: Customer Interest Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-45-002A > May > 10 > Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: Customer Interest Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's Wiring Harness: All Technical Service Bulletins Restraint System - Air Bag Warning Lamp On Repeat DTC's TECHNICAL Bulletin No.: 11-09-41-002 Date: March 17, 2011 Subject: Air Bag Warning Lamp Illuminated, Repeat History DTC B0083 0F - B0088 0F (Follow SI and Procedure Outlined Below if necessary) Models: 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT, Escalade Hybrid 2010-2011 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2010-2011 GMC Sierra, Sierra Denali, Sierra Hybrid, Yukon, Yukon XL, Yukon XL Denali, Yukon Hybrid, Yukon Denali Hybrid Condition In extremely rare cases, some customers may comment that the air bag warning lamp is illuminated. This condition may be intermittent and when checking the vehicle for DTCs, the SDM may report B0083, B0084, B0085, B0086, B0087 and/or B0088 with symptom code 0F. The code will be stored in history and may be repeated. The code probably will not be current. Cause This condition may be caused by possible electro-magnetic interference (EMI) in the Amarillo, Texas area from external sources such as aviation airspace traffic radar, creating erratic sensor information to the SDM. Correction Perform all diagnostics and repairs documented in SI. Notice If published SI repair information does not resolve the condition, perform the procedure below. Install a steward clamp ferrite bead following the procedure below: 1. Disconnect battery. Refer to SIR Disabling and Enabling in SI. 2. Remove the door trim. Refer to SI door trim removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's > Page 12349 3. Install the steward clamp ferrite bead on the wire harness (1). 4. Place tape around the steward clamp ferrite bead (1) to avoid vibration or movement. Verify that the door glass does not come in contact with it. 5. Reinstall the door trim. Refer to SI door trim removal. 6. Reconnect the battery. Refer to SIR Disabling and Enabling in SI. Parts Information Parts (Laird HFA100049-0A2) can be purchased from Digi-Key Corporation at www.digikey.com. Material allowance for repair is $1.10 each (in Canada, $1.21). Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative > Page 12354 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12359 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12360 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12361 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12362 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12367 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12368 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12369 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12374 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12375 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12376 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12377 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12378 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12379 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 12384 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10157 > May > 10 > Campaign - Engine Harness Connection Not Latched Wiring Harness: All Technical Service Bulletins Campaign - Engine Harness Connection Not Latched SERVICE UPDATE Bulletin No.: 10157 Date: May 24, 2010 Subject: 10157 - Service Update for Inventory and Customer Vehicles - Chassis-to-Engine Harness Connection Not Latched - Expires with Base Warranty Models: 2010 Chevrolet Silverado 2010 GMC Sierra 1500 Series This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to inspect the connection of the chassis-to-engine wire harness connection. If the chassis 12-way connector is not fully seated, connected and latched to the mating engine harness connector, it could create an electrical issue that would be difficult for technicians to diagnose. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers using WINS) or the Investigate Vehicle History link (dealers using GWM). Not all vehicles within the above breakpoints may be involved. Parts Information No parts are required for this update. Service Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10157 > May > 10 > Campaign - Engine Harness Connection Not Latched > Page 12389 1. Locate the chassis 12-way connector (1). The connector is located on the top of the driver's side shock tower. Refer to illustration. 2. Determine if the chassis 12-way connector is fully seated, connected and latched to the mating engine harness connector. - If the 12-way connector is properly connected, no further action is required. - If the 12-way connector is NOT properly connected, proceed to Step 3. 3. Carefully remove the 12-way connector from the shock tower. 4. Seat the 12-way connector face (2) as shown in illustration. 5. Reconnect the 12-way connector. Ensure that the connector is fully seated, connected and latched to the mating engine harness connector. 6. Re-install the 12-way connector on the shock tower. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative > Page 12394 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-08-45-002A > May > 10 > Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: All Technical Service Bulletins Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-08-45-002A > May > 10 > Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: All Technical Service Bulletins Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's Wiring Harness: All Technical Service Bulletins Restraint System - Air Bag Warning Lamp On Repeat DTC's TECHNICAL Bulletin No.: 11-09-41-002 Date: March 17, 2011 Subject: Air Bag Warning Lamp Illuminated, Repeat History DTC B0083 0F - B0088 0F (Follow SI and Procedure Outlined Below if necessary) Models: 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT, Escalade Hybrid 2010-2011 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2010-2011 GMC Sierra, Sierra Denali, Sierra Hybrid, Yukon, Yukon XL, Yukon XL Denali, Yukon Hybrid, Yukon Denali Hybrid Condition In extremely rare cases, some customers may comment that the air bag warning lamp is illuminated. This condition may be intermittent and when checking the vehicle for DTCs, the SDM may report B0083, B0084, B0085, B0086, B0087 and/or B0088 with symptom code 0F. The code will be stored in history and may be repeated. The code probably will not be current. Cause This condition may be caused by possible electro-magnetic interference (EMI) in the Amarillo, Texas area from external sources such as aviation airspace traffic radar, creating erratic sensor information to the SDM. Correction Perform all diagnostics and repairs documented in SI. Notice If published SI repair information does not resolve the condition, perform the procedure below. Install a steward clamp ferrite bead following the procedure below: 1. Disconnect battery. Refer to SIR Disabling and Enabling in SI. 2. Remove the door trim. Refer to SI door trim removal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's > Page 12408 3. Install the steward clamp ferrite bead on the wire harness (1). 4. Place tape around the steward clamp ferrite bead (1) to avoid vibration or movement. Verify that the door glass does not come in contact with it. 5. Reinstall the door trim. Refer to SI door trim removal. 6. Reconnect the battery. Refer to SIR Disabling and Enabling in SI. Parts Information Parts (Laird HFA100049-0A2) can be purchased from Digi-Key Corporation at www.digikey.com. Material allowance for repair is $1.10 each (in Canada, $1.21). Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative > Page 12413 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12418 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12419 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12424 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12425 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12426 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12431 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12432 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12433 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12434 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12435 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12436 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 12441 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative > Page 12446 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 08-08-45-002A > May > 10 > Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: All Technical Service Bulletins Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 08-08-45-002A > May > 10 > Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: All Technical Service Bulletins Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12460 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12461 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12462 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12463 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12464 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12465 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10157 > May > 10 > Campaign - Engine Harness Connection Not Latched Wiring Harness: All Technical Service Bulletins Campaign - Engine Harness Connection Not Latched SERVICE UPDATE Bulletin No.: 10157 Date: May 24, 2010 Subject: 10157 - Service Update for Inventory and Customer Vehicles - Chassis-to-Engine Harness Connection Not Latched - Expires with Base Warranty Models: 2010 Chevrolet Silverado 2010 GMC Sierra 1500 Series This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to inspect the connection of the chassis-to-engine wire harness connection. If the chassis 12-way connector is not fully seated, connected and latched to the mating engine harness connector, it could create an electrical issue that would be difficult for technicians to diagnose. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers using WINS) or the Investigate Vehicle History link (dealers using GWM). Not all vehicles within the above breakpoints may be involved. Parts Information No parts are required for this update. Service Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10157 > May > 10 > Campaign - Engine Harness Connection Not Latched > Page 12470 1. Locate the chassis 12-way connector (1). The connector is located on the top of the driver's side shock tower. Refer to illustration. 2. Determine if the chassis 12-way connector is fully seated, connected and latched to the mating engine harness connector. - If the 12-way connector is properly connected, no further action is required. - If the 12-way connector is NOT properly connected, proceed to Step 3. 3. Carefully remove the 12-way connector from the shock tower. 4. Seat the 12-way connector face (2) as shown in illustration. 5. Reconnect the 12-way connector. Ensure that the connector is fully seated, connected and latched to the mating engine harness connector. 6. Re-install the 12-way connector on the shock tower. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 12476 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 12477 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 12478 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 12479 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 12480 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 12481 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 12482 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications > Page 12485 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications > Page 12486 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 12489 Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 12490 Alignment: Description and Operation Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 12491 Alignment: Description and Operation Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 12492 Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Toe Description Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 12493 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 12494 Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if equipped. Wander Description Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 12495 Alignment: Testing and Inspection Trim Height Inspection Note: Before performing any of the following adjustment procedures, inspect the entire suspension system for worn or damaged suspension components. Replace those components before any measurements or adjustments are performed. Also check for any collision damage. Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause the vehicle to bottom over bumps, damage to the suspension components, and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: * Ensure the vehicle is on a level surface, such as an alignment rack. * Set the tire pressures to the pressure shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). * Ensure that the suspension is fully supporting the vehicle. * If the vehicle is equipped with automatic level control, ensure that the system is functioning properly. * Check for installed after market accessories or modifications that could affect trim height measurements: - Tire and wheel sizes other than production - Lifting or lowering kits - Wheel Opening Flares - Ground Effects * Ensure that the passenger and rear compartments are empty, except for the spare tire. * Check the fuel level. Add additional weight if necessary to simulate a full tank of fuel. (One U.S. gallon of gasoline weighs approximate 6.5 lbs. One liter of gasoline weighs 0.70 kg.) * Close all doors, lift gate/trunk and the hood. * Remove the alignment rack floating pins. Z Height Measurement Note: For vehicles equipped with torsion bars, check the Z height before performing the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use adjust arms in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Jounce the front suspension of the vehicle by pushing the vehicle down and lifting up. 2. Allow the vehicle to settle and take a measurement. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 12496 Note: Perform steps 3-9 for both sides of the vehicle. 3. Point A is the contact surface of the steering knuckle for the levels. 4. Set the top edge of the level on the reference surface of the steering knuckle (C) and extend the level directly under the front end of the front attachment bolt of the lower control arm (A). 5. While keeping the level in contact with the knuckle reference surface, adjust the level up/down until the bubble indicates it is horizontally level. 6. Measure the distance between the center of the bolt and the top of the level for your first measurement 7. Keep the top edge of the level on the reference surface of the steering knuckle (C) and move the level directly under the rear end of the rear attachment bolt of the lower control arm (B). 8. Measure the distance between the center of the bolt and the top of the level for your second measurement. 9. Average the measurements between the step 6 and step 8. 10. Record the measurement. Z Height Adjustment Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 12497 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion bar adjusting arm as needed. 2. For vehicles without torsion bars, replace worn or damaged components as necessary. D Height Measurement 1. Jounce the rear suspension of the vehicle by pushing the vehicle down and lifting up. 2. Allow the vehicle to settle and take a measurement. 3. Measure between the axle bracket and jounce bumper mount bracket as shown in graphic. 4. If any of these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement Alignment: Service and Repair Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull Correction) in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections in order to ensure correct alignment readings: * Inspect for visible damage to the suspension components and replace as necessary. * Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label) and Tire Diagnosis - Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear). * Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Specifications/Tire and Wheel Runout Specifications). * Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis). * Inspect the ball joints for looseness or wear. * Inspect the tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications (See: Steering/Specifications/Power Steering). * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Suspension Strut and Shock Absorber Testing - On Vehicle (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle). * Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Note: * Record the "Before" and "After" alignment measurements. * When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear toe adjustment first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 12500 Alignment: Service and Repair Front Caster and Camber Adjustment Front Caster and Camber Adjustment Note: Caster measurements are now relative to ground. 1. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Note: Before adjusting the caster and camber angles, jounce the front bumper 3 times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Inspection (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). 2. For an accurate reading, do not push or pull on the tires during the alignment process. 3. Determine the caster angle (2). 4. Determine the positive camber (2) or negative camber (3) angle. 5. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 6. Loosen the upper control arm cam adjustment bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met. When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 12501 Tighten the cam nuts to 190 Nm (140 lb ft). 8. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). When the caster and camber are within specifications, adjust the toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 12502 Alignment: Service and Repair Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment 1. Loosen the jam nut on the inner tie rod (1). 2. Rotate the inner tie rod (2) to the required toe specification setting. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the jam nut (1) on the tie rod and tighten to 75 Nm (55 lb ft). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Wheel Heater Control Module > Component Information > Service and Repair Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Module: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Module: > 10-03-16-001 > Jul > 10 > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tire Pressure Module: > 10-03-16-001 > Jul > 10 > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Customer Interest for Tire Pressure Monitor Receiver / Transponder: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Monitor Receiver / Transponder: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12551 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12552 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12553 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12554 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12555 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12556 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12563 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12564 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12565 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12566 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12567 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12568 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 12574 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 12575 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 12578 Tighten the sensor nut to 7 Nm (62 lb in). Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Wheels and Tires/Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 12579 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 12580 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in). Note: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Note: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 12581 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Wheels and Tires/Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair Center Link: Service and Repair Relay Rod Replacement Special Tools J 24319-B - Steering Linkage and Tie Rod Puller Removal Procedure 1. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 2. Remove the steering linkage shock absorber from the relay rod, if equipped. Refer to Steering Linkage Shock Absorber Replacement (See: Steering Damper/Service and Repair). 3. Remove the steering linkage outer tie rods. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 4. Remove the idler arm nut (6). Discard the nut. 5. Separate the idler arm (1) from the relay rod (5) using the J 24319-B - Puller. 6. Remove the pitman arm nut (4). Discard the nut. 7. Separate the pitman arm (2) from the relay rod using the J 24319-B - Puller. 8. Remove the relay rod from the vehicle. 9. Inspect the threads and seals on all steering related components. Repair or replace the components as necessary. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Page 12586 1. Position the relay rod (5) in the vehicle. 2. Install the pitman arm (2) to the relay rod (5). 3. Install the idler arm (1) to the relay rod. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install a NEW pitman arm nut (4) and tighten to 62 Nm (46 lb ft). 5. Install a NEW idler arm nut (6) and tighten to 62 Nm (46 lb ft). 6. Install the steering linkage outer tie rods. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 7. Install the steering linkage shock absorber to the relay rod, if equipped. Refer to Steering Linkage Shock Absorber Replacement (See: Steering Damper/Service and Repair). 8. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 9. Measure the wheel alignment. Refer to Wheel Alignment Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement). 10. Adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection Idler Arm: Testing and Inspection Idler Arm Inspection Special Tools * J 35999 Spring Scale * J 42640 Steering Column Anti-Rotation Pin * J 45101 Hub and Wheel Runout Gauge 1. Raise the vehicle on a hoist and support it with jackstands. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 2. Position the wheels straight-ahead and install anti-rotation pin J 42640 . 3. Install runout gauge J 45101 between the idler arm and the vehicle frame. Ensure the runout gauge is at zero before taking the measurement. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 12590 4. Place scale J 35999 near the relay rod end of the idler arm. 5. Exert a 110 Nm (25 lb) force upward and then downward while measuring the total distance the idler arm moves. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 12591 6. If the movement exceeds 2 mm (0.078 in) then replace the idler arm. 7. Install the runout gauge at the idler arm. 8. Push the tire inward slowly with one hand to remove any lash. Zero out the runout gauge and pull outward in order to take a reading. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 12592 9. Allow only 1 mm (0.039 in) of movement at the idler arm ball stud. If the movement is more than 1 mm (0.039 in) then replace the idler arm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 12593 Idler Arm: Service and Repair Idler Arm Replacement Special Tools J 24319-B Steering Linkage and Tie Rod Puller Removal Procedure Caution: Do not attempt to free the ball stud by using a pickle fork or wedge type tool, because seal or bushing damage could result. Use the proper tool to separate all ball joints. 1. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). Note: Discard the idler arm nut. 2. Remove the idler arm nut (3) from the idler arm (1). 3. Separate the idler arm (1) from the relay rod (2). 4. Remove the idler arm from the relay rod using puller J 24319-B . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 12594 5. Remove the idler arm bolts (3) and the nuts (1) at the vehicle frame. 6. Remove the idler arm (2) from the vehicle. Installation Procedure 1. Position the idler arm (2) to the vehicle frame. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the idler arm bolts (3) and nuts (1) to the frame and tighten to 105 Nm (78 lb ft). 3. Install the idler arm (1) to the relay rod (2). Note: Do not reuse the old idler arm nut. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 12595 4. Install the new idler arm nut (3) to the idler arm (1) and tighten to 62 Nm (46 lb ft). 5. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 6. Adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Steering/Suspension - Pitman Arm Shaft Seal Service Kit Pitman Arm: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 12600 Pitman Arm: Service and Repair Pitman Arm Replacement Special Tools * J 6632-01 Pitman Arm Puller * J 29107-A Pitman Arm Puller Removal Procedure 1. Remove the steering gear. Refer to Steering Gear Replacement (Hydraulic Rack and Pinion) (See: Steering Gear)Steering Gear Replacement (Recirculating Ball Without LMM) (See: Steering Gear)Steering Gear Replacement (HP2) (See: Steering Gear)Steering Gear Replacement (LMM) (See: Steering Gear). 2. Place the steering gear into a vise. 3. Remove the pitman arm nut (1) and washer (2). 4. Remove the pitman arm from the pitman arm shaft using puller J 6632-01 or puller J 29107-A . Installation Procedure 1. Install the pitman arm onto the steering gear. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 12601 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install a new pitman arm washer (2) and nut (1). Tighten the nut to 250 Nm (184 lb ft). 3. Remove the steering gear from the vise. 4. Install the steering gear. Refer to Steering Gear Replacement (Hydraulic Rack and Pinion) (See: Steering Gear)Steering Gear Replacement (Recirculating Ball Without LMM) (See: Steering Gear)Steering Gear Replacement (HP2) (See: Steering Gear)Steering Gear Replacement (LMM) (See: Steering Gear). 5. Adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Power Steering System Bleeding Important: * Use clean, new power steering fluid type only. See the Maintenance and Lubrication subsection for fluid specifications. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). * Hoses touching the frame, body or engine may cause system noise. Verify that the hoses do not touch any other part of the vehicle. * Loose connections may not leak, but could allow air into the steering system. Verify that all hose connections are tight. Important: Power steering fluid level must be maintained throughout bleed procedure. 1. Fill pump reservoir with fluid to minimum system level, FULL COLD level, or middle of hash mark on cap stick fluid level indicator. Important: With hydro-boost only, the oil level will appear falsely high if the hydro-boost accumulator is not fully charged. Do not apply the brake pedal with the engine OFF. This will discharge the hydro-boost accumulator. 2. If equipped with hydro-boost, fully charge the hydro-boost accumulator using the following procedure: 1. Start the engine. 2. Firmly apply the brake pedal 10-15 times. 3. Turn the engine OFF. 3. Raise the vehicle until the front wheels are off the ground. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 4. Key on engine OFF, turn the steering wheel from stop to stop 12 times. Vehicles equipped with hydro-boost systems or longer length power steering hoses may require turns up to 15 to 20 stop to stops. 5. Verify power steering fluid level per operating specification. Refer to Checking and Adding Power Steering Fluid (Without Hydroboost) (See: Service and Repair/Checking and Adding Power Steering Fluid (Without Hydroboost))Checking and Adding Power Steering Fluid (With Hydroboost) (See: Service and Repair/Checking and Adding Power Steering Fluid (With Hydroboost)). 6. Start the engine. Rotate steering wheel from left to right. Check for sign of cavitation or fluid aeration (pump noise/whining). 7. Verify the fluid level. Repeat the bleed procedure, if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Power Steering Fluid Cooler Replacement (Without Hydroboost) Power Steering Fluid Cooler: Service and Repair Power Steering Fluid Cooler Replacement (Without Hydroboost) Power Steering Fluid Cooler Replacement (Without Hydroboost) Removal Procedure 1. Remove the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Remove as much power steering fluid as possible from the power steering fluid reservoir. 3. Place drain pans under the vehicle as needed. Caution: Refer to Power Steering Hose Disconnected Caution (See: Power Steering Line/Hose/Service Precautions). 4. Disconnect the power steering gear outlet hose (2) from the power steering fluid cooler (4). 5. Disconnect the power steering fluid cooler hose (3) from the power steering pump (1). 6. Remove the power steering fluid cooler bolts (2) from the power steering fluid cooler (1). 7. Remove the power steering fluid cooler from the vehicle. Installation Procedure 1. Install the power steering fluid cooler to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Power Steering Fluid Cooler Replacement (Without Hydroboost) > Page 12613 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the power steering fluid cooler bolts (2) to the power steering fluid cooler (1). Tighten the bolts to 9 Nm (80 lb in). 3. Connect the power steering fluid cooler hose (3) to the power steering pump (1). 4. Connect the power steering gear outlet hose (2) to the power steering fluid cooler (4). 5. Clean any excess fluid from the vehicle and remove the drain pans. 6. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair). 7. Install the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Power Steering Fluid Cooler Replacement (Without Hydroboost) > Page 12614 Power Steering Fluid Cooler: Service and Repair Power Steering Fluid Cooler Replacement (With Hydroboost) Power Steering Fluid Cooler Replacement (With Hydroboost) Removal Procedure 1. Remove the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Remove as much power steering fluid from the power steering fluid reservoir as possible. 3. Place drain pans under the vehicle as needed. Caution: Refer to Power Steering Hose Disconnected Caution (See: Power Steering Line/Hose/Service Precautions). 4. Disconnect the power steering fluid cooler hose (3) from the steering gear (2). 5. Disconnect the power steering fluid cooler hose (4) from the power steering pump (1). 6. Remove the power steering fluid cooler bolts (2). 7. Remove the power steering fluid cooler (1) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Power Steering Fluid Cooler Replacement (Without Hydroboost) > Page 12615 1. Install the power steering fluid cooler (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the power steering fluid cooler bolts (2). Tighten the bolts to 9 Nm (80 lb in) 3. Connect the power steering fluid cooler hose (4) to the power steering pump (1). 4. Connect the power steering fluid cooler hose (3) to the steering gear (2). 5. Clean any excess fluid from the vehicle and remove the drain pans. 6. Install the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 7. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations Power Steering Fluid Reservoir: Locations Power Steering Pump Disassembled View 1 - Power Steering Fluid Reservoir 2 - Power Steering Fluid Reservoir Cap 3 - Power Steering Fluid Reservoir Stud 4 - Power Steering Fluid Reservoir Stud 5 - Power Steering Pump Fitting 6 Power Steering Pump Fitting Seal 7 - Power Steering Pump Flow Control Valve 8 - Power Steering Pump Flow Control Valve Spring 9 - Power Steering Pump Housing Seal 10 - Power Steering Pump Housing Seals 11 - Power Steering Fluid Reservoir Seal 12 - Power Steering Pump 13 Power Steering Pump Shaft Seal 14 - Power Steering Fluid Reservoir Magnet Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations > Page 12619 Power Steering Fluid Reservoir: Service and Repair Power Steering Fluid Reservoir Replacement - Off Vehicle Disassembly Procedure 1. Remove the power steering pump assembly from the vehicle. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Power Steering Pump/Service and Repair)Power Steering Pump Replacement (4.3L) (See: Power Steering Pump/Service and Repair)Power Steering Pump Replacement (6.6L) (See: Power Steering Pump/Service and Repair). 2. Remove the power steering fluid reservoir studs (2) from the power steering pump assembly (1). 3. Remove the power steering pump fitting (4). 4. Remove the power steering pump fitting seal (3). 5. Remove the power steering pump flow control valve (2) and the power steering pump flow control valve spring (3) from the power steering pump assembly (1). 6. Separate the power steering fluid reservoir (1) and the power steering pump (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations > Page 12620 7. Remove the power steering pump seals (1, 4, 5). 8. Remove and clean the power steering fluid reservoir magnet (3). 9. Inspect the welch plug in the power steering pump (2). DO NOT REMOVE IT. If the welch plug is deformed or dislodged then replace the power steering pump (2). Assembly Procedure 1. Clean and install the power steering fluid reservoir magnet (3). 2. Install the power steering pump seals (1, 4, 5) to the power steering pump (2). 3. Connect the power steering fluid reservoir (1) and the power steering pump (2). 4. Install the power steering pump flow control valve spring (3) and the power steering pump flow control valve (2) to the power steering pump assembly (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations > Page 12621 5. Install the power steering pump fitting seal (3) to the power steering pump assembly (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Start the power steering fluid reservoir studs and the power steering pump flow control valve fitting by hand before finalizing any torques. 6. Install the power steering pump fitting (4) to the power steering pump assembly (1). Tighten the fitting to 75 Nm (55 lb ft). 7. Install the power steering fluid reservoir studs (2) to the power steering pump assembly (1). Tighten the studs to 58 Nm (44 lb ft). 8. Install the power steering pump assembly to the vehicle. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Power Steering Pump/Service and Repair)Power Steering Pump Replacement (4.3L) (See: Power Steering Pump/Service and Repair)Power Steering Pump Replacement (6.6L) (See: Power Steering Pump/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 07-02-32-002J > Jul > 10 > Steering/Suspension - Power Steering Fluid Leaking Power Steering Line/Hose: Customer Interest Steering/Suspension - Power Steering Fluid Leaking ENGINEERING INFORMATION Bulletin No.: 07-02-32-002J Date: July 23, 2010 Subject: EI07082 - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly (Engineering Recommendations / Engineering Information Closed) Models: 2008-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 GMC Denali, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series Only and Excluding Hybrids Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-02-32-002I (Section 02 - Steering). Condition Some customers may comment on a fluid leak. Upon investigation, the technician may find fluid leaking from the power steering system. Please use the following information to assist in diagnosis. Diagnostic Information Important All potential leaks should be completely cleaned and identified before attempting to repair or replace any power steering components. 1. Start diagnosis by inspecting the fluid level in the power steering reservoir. If the fluid level is NOT low, a careful analysis of the condition is necessary as it may involve a different type of fluid leak. 2. Visually inspect the components where the fluid has accumulated. 3. Completely clean off any fluid residue from the suspect components. 4. Apply tracing powder to the suspect components. This is an effective way to determine the source of a leak. As an alternative, fluorescent dye (such as Kent Moore J 28431-6) may be added to the power steering fluid. 5. Start the vehicle and allow the power steering system to reach normal operating temperatures. 6. Turn the steering wheel to the stops in each direction while bumping the steering wheel against the stops 3-4 times. This will build maximum steering system pressure and help identify the source of the leak if present. 7. Determine the source of the leak. 8. If a repeatable leak is found, refer to the following tables to determine the proper corrective action needed. Repairable Leaks Non- Repairable Leaks *If fluid is observed at the adjuster plug during the initial visual inspection, then refer to the following: - Seepage at the adjuster plug may not necessarily indicate an active leak. Power steering fluid is used during the manufacturing of the gear/rack. The fluid used at assembly is pushed into the pinion area during assembly. The adjuster plug and the area below the pinion are not positively Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 07-02-32-002J > Jul > 10 > Steering/Suspension - Power Steering Fluid Leaking > Page 12630 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 07-02-32-002J > Jul > 10 > Steering/Suspension - Power Steering Fluid Leaking Power Steering Line/Hose: All Technical Service Bulletins Steering/Suspension - Power Steering Fluid Leaking ENGINEERING INFORMATION Bulletin No.: 07-02-32-002J Date: July 23, 2010 Subject: EI07082 - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly (Engineering Recommendations / Engineering Information Closed) Models: 2008-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 GMC Denali, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series Only and Excluding Hybrids Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-02-32-002I (Section 02 - Steering). Condition Some customers may comment on a fluid leak. Upon investigation, the technician may find fluid leaking from the power steering system. Please use the following information to assist in diagnosis. Diagnostic Information Important All potential leaks should be completely cleaned and identified before attempting to repair or replace any power steering components. 1. Start diagnosis by inspecting the fluid level in the power steering reservoir. If the fluid level is NOT low, a careful analysis of the condition is necessary as it may involve a different type of fluid leak. 2. Visually inspect the components where the fluid has accumulated. 3. Completely clean off any fluid residue from the suspect components. 4. Apply tracing powder to the suspect components. This is an effective way to determine the source of a leak. As an alternative, fluorescent dye (such as Kent Moore J 28431-6) may be added to the power steering fluid. 5. Start the vehicle and allow the power steering system to reach normal operating temperatures. 6. Turn the steering wheel to the stops in each direction while bumping the steering wheel against the stops 3-4 times. This will build maximum steering system pressure and help identify the source of the leak if present. 7. Determine the source of the leak. 8. If a repeatable leak is found, refer to the following tables to determine the proper corrective action needed. Repairable Leaks Non- Repairable Leaks *If fluid is observed at the adjuster plug during the initial visual inspection, then refer to the following: - Seepage at the adjuster plug may not necessarily indicate an active leak. Power steering fluid is used during the manufacturing of the gear/rack. The fluid used at assembly is pushed into the pinion area during assembly. The adjuster plug and the area below the pinion are not positively Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 07-02-32-002J > Jul > 10 > Steering/Suspension - Power Steering Fluid Leaking > Page 12636 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 12637 Power Steering Line/Hose: Service Precautions Power Steering Hose Disconnected Caution Caution: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid and damage to the system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Install drain pans under the vehicle as needed. Caution: Refer to Power Steering Hose Disconnected Caution (See: Service Precautions). Note: Note the routing of the power steering gear inlet hose before removal. It MUST be routed correctly upon installation. 2. Remove the power steering gear inlet hose (2) from the power brake booster (1). 3. Remove the power steering gear inlet hose (2) from the power steering gear. 4. Remove the power steering gear inlet hose (2) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 12640 Caution: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Note: The power steering gear inlet hose cannot be routed between the brake lines and the power brake booster during installation. 1. Route the power steering gear inlet hose in the same position it was in prior to removal. 2. Install the power steering gear inlet hose (2) to the power brake booster (1) and hand tighten only. Rotate the power steering gear inlet hose clockwise until the it contacts the power brake booster housing and then hold it in position while tightening it to the fitting specification. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the power steering gear inlet hose (2) to the power steering gear. Tighten the fittings to 32 Nm (24 lb ft). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 12641 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 12642 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Place drain pans under the vehicle as needed. Caution: Refer to Power Steering Hose Disconnected Caution (See: Service Precautions). 2. Disconnect the power steering fluid cooler hose clamp and hose (3) from the steering gear (2). 3. Remove the power steering gear outlet pipe (1) from the steering gear (2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 12643 1. Install the power steering gear outlet pipe (1) to the steering gear (2). 2. Connect the power steering fluid cooler hose (3) and hose clamp to the steering gear (2). 3. Clean any excess fluid from the vehicle and remove the drain pans. 4. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair) . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 12644 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 12645 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Install drain pans under the vehicle as needed. Caution: Refer to Power Steering Hose Disconnected Caution (See: Service Precautions). Note: Note the routing of the power steering gear inlet hose before removal. It MUST be routed correctly upon installation. 2. Remove the power steering gear inlet hose (2) from the power brake booster (1). 3. Remove the power steering gear inlet hose (2) from the power steering gear. 4. Remove the power steering gear inlet hose (2) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 12646 Caution: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Note: The power steering gear inlet hose cannot be routed between the brake lines and the power brake booster during installation. 1. Route the power steering gear inlet hose in the same position it was in prior to removal. 2. Install the power steering gear inlet hose (2) to the power brake booster (1) and hand tighten only. Rotate the power steering gear inlet hose clockwise until the it contacts the power brake booster housing and then hold it in position while tightening it to the fitting specification. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the power steering gear inlet hose (2) to the power steering gear. Tighten the fittings to 32 Nm (24 lb ft). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair). Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 12647 Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Place drain pans under the vehicle as needed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 12648 Caution: Refer to Power Steering Hose Disconnected Caution (See: Service Precautions). 2. Disconnect the power steering fluid cooler hose clamp and hose (3) from the steering gear (2). 3. Remove the power steering gear outlet pipe (1) from the steering gear (2). Installation Procedure 1. Install the power steering gear outlet pipe (1) to the steering gear (2). 2. Connect the power steering fluid cooler hose (3) and hose clamp to the steering gear (2). 3. Clean any excess fluid from the vehicle and remove the drain pans. 4. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair) . Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 12649 Power Steering Gear Outlet Pipe/Hose Replacement (Diesel) Power Steering Gear Outlet Pipe/Hose Replacement (Diesel) Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 12650 1. Remove as much power steering fluid from the power steering fluid reservoir as possible. 2. Place drain pans under the vehicle as needed. 3. Compress the power steering gear outlet hose clamp (2). 4. Disconnect the power steering gear outlet hose (1) from the power steering pump assembly (3). 5. Disconnect the power steering gear outlet hose (2) from the steering gear (1). 6. Remove the power steering gear outlet hose (1) from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 12651 1. Install the power steering gear outlet hose (1) to the vehicle. 2. Connect the power steering gear outlet hose (2) to the steering gear (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Compress the power steering gear outlet hose clamp (2). 4. Connect the power steering gear outlet hose (1) to the power steering pump assembly (3). Tighten the fitting to 32 Nm (24 lb ft). 5. Clean any excessive power steering fluid from the vehicle and remove the drain pans. 6. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair). Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 12652 Removal Procedure 1. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 2. Place drain pans under the vehicle as needed. 3. Remove as much power steering fluid from the power steering fluid reservoir as possible. Caution: Refer to Power Steering Hose Disconnected Caution (See: Service Precautions). 4. Disconnect the power brake booster inlet hose from the power steering pump (3). 5. Disconnect the power brake booster inlet hose (1) from the power brake booster (2). 6. Remove the power brake booster inlet hose (1) from the vehicle. Installation Procedure Caution: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. 1. Install the power brake booster inlet hose (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Start both power brake booster inlet hose fittings by hand before finalizing torques. 2. Connect the power brake booster inlet hose (1) to the power brake booster (2). Tighten the fitting to 32 Nm (24 lb ft). 3. Connect the power brake booster inlet hose (1) to the power steering pump (3). Tighten the fitting to 32 Nm (24 lb ft). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 6. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair). Power Brake Booster Outlet Hose Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) > Page 12653 Power Brake Booster Outlet Hose Replacement Removal Procedure 1. Place drain pans under the vehicle as needed. 2. Remove as much power steering fluid from the power steering fluid reservoir as possible. Caution: Refer to Power Steering Hose Disconnected Caution (See: Service Precautions). 3. Disconnect the power brake booster outlet hose (1) from the power brake booster (2). 4. Disconnect the power brake booster outlet hose (1) from the power steering fluid reservoir (3). 5. Remove the power brake booster outlet hose (1) from the vehicle. Installation Procedure Caution: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. 1. Install the power brake booster outlet hose (1) to the vehicle. 2. Connect the power brake booster outlet hose (1) to the power steering fluid reservoir (3). 3. Connect the power brake booster outlet hose (1) to the power brake booster (2). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Service and Repair Power Steering Pressure Control Valve: Service and Repair Power Steering Pump Flow Control Valve Replacement - Off Vehicle Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Power Steering Pump Seal > Component Information > Service and Repair Power Steering Pump Seal: Service and Repair Power Steering Pump Shaft Seal Replacement Removal Procedure 1. Remove the power steering pump from the vehicle. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Service and Repair)Power Steering Pump Replacement (4.3L) (See: Service and Repair)Power Steering Pump Replacement (6.6L) (See: Service and Repair ). Important: Use the shim stock in order to protect the drive shaft. 2. Use a chisel in order to cut and remove the power steering pump shaft seal. Installation Procedure 1. Lubricate the new power steering pump shaft seal with power steering fluid. 2. Use a deep 1 inch tall socket in order to install the new power steering pump shaft seal. 3. Install the power steering pump. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Service and Repair)Power Steering Pump Replacement (4.3L) (See: Service and Repair)Power Steering Pump Replacement (6.6L) (See: Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Wheel Heater Control Module > Component Information > Service and Repair Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12671 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12672 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12673 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12674 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12675 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12676 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12682 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12683 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12684 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12685 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12686 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12687 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 12692 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Service and Repair Steering Damper: Service and Repair Steering Linkage Shock Absorber Replacement Special Tools J 24319-B Steering Linkage and Tie Rod Puller Removal Procedure 1. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). Note: Discard the steering linkage shock absorber nut. 2. Remove the steering linkage shock absorber nut (1) from the steering linkage shock absorber (2). 3. Remove the steering linkage shock absorber from the relay rod using puller J 24319-B . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Service and Repair > Page 12696 Note: Discard the steering linkage shock absorber nut. 4. Remove the steering linkage shock absorber bolt (2) and nut (3). 5. Remove the steering linkage shock absorber (1) from the vehicle. 6. Inspect the following parts: * The steering linkage shock absorber for leaks and damage * The steering linkage shock absorber bolt for damage or corrosion Installation Procedure Note: Use new steering linkage shock absorber nuts. 1. Install the steering linkage shock absorber (2) to the vehicle. 2. Install the steering linkage shock absorber (4) and nuts (1, 3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Service and Repair > Page 12697 3. Install the steering linkage shock absorber nuts (1, 3) and tighten to 40 Nm (30 lb ft). 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Technical Service Bulletins > Steering/Suspension - Pitman Arm Shaft Seal Service Kit Steering Gear Seal: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Rack Gear > Component Information > Technical Service Bulletins > Customer Interest for Steering Rack Gear: > 07-02-32-002J > Jul > 10 > Steering/Suspension - Power Steering Fluid Leaking Steering Rack Gear: Customer Interest Steering/Suspension - Power Steering Fluid Leaking ENGINEERING INFORMATION Bulletin No.: 07-02-32-002J Date: July 23, 2010 Subject: EI07082 - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly (Engineering Recommendations / Engineering Information Closed) Models: 2008-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 GMC Denali, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series Only and Excluding Hybrids Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-02-32-002I (Section 02 - Steering). Condition Some customers may comment on a fluid leak. Upon investigation, the technician may find fluid leaking from the power steering system. Please use the following information to assist in diagnosis. Diagnostic Information Important All potential leaks should be completely cleaned and identified before attempting to repair or replace any power steering components. 1. Start diagnosis by inspecting the fluid level in the power steering reservoir. If the fluid level is NOT low, a careful analysis of the condition is necessary as it may involve a different type of fluid leak. 2. Visually inspect the components where the fluid has accumulated. 3. Completely clean off any fluid residue from the suspect components. 4. Apply tracing powder to the suspect components. This is an effective way to determine the source of a leak. As an alternative, fluorescent dye (such as Kent Moore J 28431-6) may be added to the power steering fluid. 5. Start the vehicle and allow the power steering system to reach normal operating temperatures. 6. Turn the steering wheel to the stops in each direction while bumping the steering wheel against the stops 3-4 times. This will build maximum steering system pressure and help identify the source of the leak if present. 7. Determine the source of the leak. 8. If a repeatable leak is found, refer to the following tables to determine the proper corrective action needed. Repairable Leaks Non- Repairable Leaks *If fluid is observed at the adjuster plug during the initial visual inspection, then refer to the following: - Seepage at the adjuster plug may not necessarily indicate an active leak. Power steering fluid is used during the manufacturing of the gear/rack. The fluid used at assembly is pushed into the pinion area during assembly. The adjuster plug and the area below the pinion are not positively Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Rack Gear > Component Information > Technical Service Bulletins > Customer Interest for Steering Rack Gear: > 07-02-32-002J > Jul > 10 > Steering/Suspension - Power Steering Fluid Leaking > Page 12711 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Rack Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Rack Gear: > 07-02-32-002J > Jul > 10 > Steering/Suspension - Power Steering Fluid Leaking Steering Rack Gear: All Technical Service Bulletins Steering/Suspension - Power Steering Fluid Leaking ENGINEERING INFORMATION Bulletin No.: 07-02-32-002J Date: July 23, 2010 Subject: EI07082 - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly (Engineering Recommendations / Engineering Information Closed) Models: 2008-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 GMC Denali, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series Only and Excluding Hybrids Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-02-32-002I (Section 02 - Steering). Condition Some customers may comment on a fluid leak. Upon investigation, the technician may find fluid leaking from the power steering system. Please use the following information to assist in diagnosis. Diagnostic Information Important All potential leaks should be completely cleaned and identified before attempting to repair or replace any power steering components. 1. Start diagnosis by inspecting the fluid level in the power steering reservoir. If the fluid level is NOT low, a careful analysis of the condition is necessary as it may involve a different type of fluid leak. 2. Visually inspect the components where the fluid has accumulated. 3. Completely clean off any fluid residue from the suspect components. 4. Apply tracing powder to the suspect components. This is an effective way to determine the source of a leak. As an alternative, fluorescent dye (such as Kent Moore J 28431-6) may be added to the power steering fluid. 5. Start the vehicle and allow the power steering system to reach normal operating temperatures. 6. Turn the steering wheel to the stops in each direction while bumping the steering wheel against the stops 3-4 times. This will build maximum steering system pressure and help identify the source of the leak if present. 7. Determine the source of the leak. 8. If a repeatable leak is found, refer to the following tables to determine the proper corrective action needed. Repairable Leaks Non- Repairable Leaks *If fluid is observed at the adjuster plug during the initial visual inspection, then refer to the following: - Seepage at the adjuster plug may not necessarily indicate an active leak. Power steering fluid is used during the manufacturing of the gear/rack. The fluid used at assembly is pushed into the pinion area during assembly. The adjuster plug and the area below the pinion are not positively Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Rack Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Rack Gear: > 07-02-32-002J > Jul > 10 > Steering/Suspension - Power Steering Fluid Leaking > Page 12717 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Assembly > Component Information > Service and Repair Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams Steering Mounted Controls Transmitter: Diagrams Component Connector End Views Steering Wheel Control Switch - Left (K34 or KA9) Steering Wheel Control Switch - Right (UK3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 12724 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement Steering Shaft: Service and Repair Steering Shaft Upper Bearing Replacement Steering Shaft Upper Bearing Replacement Special Tools * J 21854-01 Pivot Pin Remover * J 23653-SIR Steering Column Lock Plate Compressor * J 42137 Cam Orientation Plate Adapter * J 42640 Steering Column Anti-Rotation Pin Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Remove the steering column. Refer to Steering Column Replacement (Without HP2) (See: Steering Column/Service and Repair/Steering Column Replacement (Without HP2))Steering Column Replacement (HP2) (). 2. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 3. Remove the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch Replacement (See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Turn Signal Switch/Service and Repair/Turn Signal Multifunction Switch Replacement). 4. Remove the ignition lock cylinder case. Refer to Ignition Lock Cylinder Case Replacement (See: Powertrain Management/Ignition System/Sensors and Switches - Ignition System/Ignition Switch/Ignition Switch Lock Cylinder/Service and Repair/Ignition Lock Cylinder Case Replacement). 5. Remove the tilt spring. Refer to Steering Column Tilt Spring Replacement (See: Steering Column/Service and Repair/Steering Column Tilt Spring Replacement). 6. Remove the automatic transmission control. Refer to Transmission Control Replacement (See: Steering Column/Service and Repair/Transmission Control Replacement). 7. Using compressor J 23653-SIR and adapter J 42137 , remove and discard the steering shaft lock plate retaining ring. 8. Remove the following parts from the steering column shaft assembly: 1. The turn signal switch cancel cam position plate (5) 2. The turn signal switch cancel cam (4) 3. The steering shaft upper bearing spring (3) 4. The steering shaft upper bearing inner race seat (2) 5. The steering shaft upper bearing inner race (1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12729 9. Remove the 2 pivot pins (3) from the steering column tilt head assembly (1) by using remover J 21854-01 (2). 10. Install the tilt lever into the steering column tilt head assembly (1). 11. Pull back on the tilt lever and at the same time, pull the steering column tilt head assembly (1) down and away from the steering column. 12. Remove the steering column tilt head assembly. 13. Remove anti-rotation pin J 42640 . 14. Remove the tilt lever. 15. Remove the steering shaft upper bearing from the steering column tilt head assembly. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12730 1. Install the steering shaft upper bearing to the steering column tilt head assembly. 2. Install the steering column shaft assembly. 3. Maneuver and push the steering column tilt head assembly (1) towards the steering column in order to lock the steering wheel lock shoes in place. 4. Lubricate the pivot pins (1) with GM P/N 12346293 (Canadian P/N 992723). 5. Firmly seat each pivot pin (1) into the steering column tilt head assembly. 6. Stake the steering column in 3 locations around each pivot pin. 7. Install anti-rotation pin J 42640 . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12731 8. Install the following parts onto the steering column shaft assembly: 1. Lubricate the steering shaft upper bearing inner race (1) with GM P/N 12345718 (Canadian P/N 10953516). 2. The steering shaft upper bearing inner race (1) 3. The steering shaft upper bearing inner race seat (2) 4. The steering shaft upper bearing spring (3) 5. Lubricate the turn signal switch cancel cam (4) with GM P/N 12377900 (Canadian P/N 10953529). 6. The turn signal switch cancel cam (4) 7. The turn signal switch cancel cam position plate (5) 9. Install the new steering shaft lock plate retaining ring onto the steering shaft using compressor J 23653-SIR and adapter J 42137 . 10. Install the automatic transmission control assembly. Refer to Transmission Control Replacement (See: Steering Column/Service and Repair/Transmission Control Replacement). 11. Install the tilt spring. Refer to Steering Column Tilt Spring Replacement (See: Steering Column/Service and Repair/Steering Column Tilt Spring Replacement). 12. Install the ignition lock cylinder case. Refer to Ignition Lock Cylinder Case Replacement (See: Powertrain Management/Ignition System/Sensors and Switches - Ignition System/Ignition Switch/Ignition Switch Lock Cylinder/Service and Repair/Ignition Lock Cylinder Case Replacement). 13. Install the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch Replacement (See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Turn Signal Switch/Service and Repair/Turn Signal Multifunction Switch Replacement). 14. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 15. Install the steering column. Refer to Steering Column Replacement (Without HP2) (See: Steering Column/Service and Repair/Steering Column Replacement (Without HP2))Steering Column Replacement (HP2) (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12732 Steering Shaft: Service and Repair Steering Shaft Lower Bearing Replacement Steering Shaft Lower Bearing Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12733 Steering Shaft: Service and Repair Steering Shaft Coupling Replacement Steering Shaft Coupling Replacement Special Tools J-42640 - Steering Column Anti-rotation Pin Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. Ensure the front wheels are in the straight-ahead position. 2. Install the J-42640 - pin in the steering column lower access hole. 3. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 4. Use paint in order to mark the relationship of the upper intermediate steering shaft to the steering shaft coupling. 5. Use paint in order to mark the relationship of the steering shaft coupling to the steering gear. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12734 Note: DO NOT pull on the steering shaft coupling (1) in order to separate the coupling from the steering gear. 6. Remove the steering shaft coupling bolt (2) at the steering gear. 7. Remove the steering shaft coupling nut (1) and the bolt (2) at the upper intermediate steering shaft. 8. Remove the steering shaft coupling from the vehicle. Installation Procedure Note: Failure to transfer the alignment marks may result in an off-center steering wheel after installation. 1. If a new steering shaft coupling is being installed, copy the alignment marks from the old component to the same locations on the new component. 2. Position the steering shaft coupling in the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12735 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the steering shaft coupling nut (1) and the bolt (2) to the upper intermediate steering shaft and tighten to 50 Nm (37 lb ft). 4. Install the steering shaft coupling bolt (2) to the steering gear and tighten to 47 Nm (35 lb ft). 5. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12736 6. Remove the J-42640 - pin from the steering column lower access hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Steering Wheel Heater Control Module > Component Information > Service and Repair Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and Inspection > Steering Linkage Inner Tie Rod Inspection Tie Rod: Testing and Inspection Steering Linkage Inner Tie Rod Inspection Steering Linkage Inner Tie Rod Inspection Special Tools J-8001 - Dial Indicator Set For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: This inspection procedure does not supersede local government required inspections that have more stringent requirements. 1. Turn the ignition key to the ON position with the engine OFF. 2. With the aid of an assistant, turn the steering wheel to the full stop position and hold the steering wheel in that position until the test is complete. The tie rod being tested should be inside the steering gear housing seated against the steering stop. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 4. If there is not a good location for the J-8001 - Dial Indicator pointer at the steering gear housing, install a large worm gear hose clamp to the steering gear housing over the larger steering gear boot clamp and align the clamp so that the screw can be a location for the J-8001 - Dial Indicator pointer. 5. Install the J-8001 - Dial Indicator between the inner tie rod (2) and the steering gear housing or the worm gear clamp in such a way as to measure the lash between the inner tie rod and the steering gear housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and Inspection > Steering Linkage Inner Tie Rod Inspection > Page 12745 Note: Only move the tire enough to feel any lash between the inner tie rod and the inner tie rod housing without moving the steering gear rack. 6. Grasping the tire at the 3 o'clock (2) and 9 o'clock (1) positions, gently push in on one side of the tire in order to remove any lash. 7. Zero the J-8001 - Dial Indicator. 8. On the same side of the tire previously pushed in, gently pull out and measure the lash. 9. Record the measurement seen on the J-8001 - Dial Indicator. 10. If the measured value exceeds 0.5 mm (0.02 in), replace the inner tie rod. Refer to Steering Linkage Inner Tie Rod Replacement (HP2) ()Steering Linkage Inner Tie Rod Replacement (Hydraulic Rack and Pinion) (See: Service and Repair/Steering Linkage Inner Tie Rod Replacement (Hydraulic Rack and Pinion)). 11. Repeat the procedure for the other side. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and Inspection > Steering Linkage Inner Tie Rod Inspection > Page 12746 Tie Rod: Testing and Inspection Steering Linkage Outer Tie Rod Inspection Steering Linkage Outer Tie Rod Inspection Special Tools J-8001 - Dial Indicator Set For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: This inspection procedure does not supersede local government required inspections that have more stringent requirements. 1. Inspect the outer tie rod end seal. If the outer tie rod end seal is torn, replace the outer tie rod end. Refer to Steering Linkage Outer Tie Rod Replacement (See: Service and Repair/Steering Linkage Outer Tie Rod Replacement). 2. Raise the side of the vehicle being inspected with a floor jack while maintaining contact between the opposite wheel and the shop floor. Support the lower control arm with a floor jack stand as far outboard as possible and remove the floor jack. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 3. Install the J-8001 - Dial Indicator between the outer tie rod end and the steering knuckle as shown in the graphic. Note that the tire and wheel assembly is shown removed only for clarification of the dial indicator position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and Inspection > Steering Linkage Inner Tie Rod Inspection > Page 12747 4. Grasping the tire at the 3 o'clock (2) and 9 o'clock (1) positions, gently push in on one side of the tire to remove any lash. 5. Zero the J-8001 - Dial Indicator. 6. On the same side of the tire previously pushed inwards, gently pull outwards and measure the lash. 7. Record the measurement seen on the J-8001 - Dial Indicator. 8. If the measured value exceeds 1 mm (0.04 in) then replace the outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Service and Repair/Steering Linkage Outer Tie Rod Replacement). 9. Repeat the procedure for the other side. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement Tie Rod: Service and Repair Steering Linkage Outer Tie Rod Replacement Power Steering Steering Linkage Outer Tie Rod Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 12750 Steering Linkage Steering Linkage Outer Tie Rod Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 12751 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 12752 Tie Rod: Service and Repair Steering Linkage Inner Tie Rod Replacement (Hydraulic Rack and Pinion) Steering Linkage Inner Tie Rod Replacement (Hydraulic Rack and Pinion) Removal Procedure Note: After removing the boot, inspect the inner tie rod for evidence of corrosion or contamination. If none is evident, continue with the repair. If corrosion or contamination is evident, replace the steering gear. 1. Remove the steering gear boot. Refer to Steering Gear Boot Replacement (HP2) (See: Steering Gear)Steering Gear Boot Replacement (Without HP2) (See: Steering Gear). Caution: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod could result in damage to the pinion and the steering gear. Caution: The pipe wrench must be placed at the valve end of the steering gear and positioned up against the inner tie rod housing. Placing the pipe wrench in any other location will cause damage to the steering gear. 2. Place a pipe wrench on the steering gear rack (1) next to the steering linkage inner tie rod housing (2). 3. Place a wrench on the flats of the steering linkage inner tie rod housing (2). 4. Rotate the steering linkage inner tie rod housing (2) counterclockwise, while holding the steering gear rack stationary, until the steering linkage inner tie rod separates from the steering gear rack (1). Installation Procedure Note: All threads must be clean prior to LOCTITE(R) application. Check the LOCTITE(R), or equivalent, container for the expiration date. Use only enough LOCTITE(R) to evenly coat the threads. 1. Apply LOCTITE(R) 262, or equivalent, to the steering gear inner tie rod threads. 2. Attach the steering linkage inner tie rod onto the steering gear rack. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 12753 Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage Warnings/Pipe Wrench Positioning Caution). 3. Place a pipe wrench on the steering gear rack (1) next to the steering linkage inner tie rod housing (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 4. Tighten the steering linkage inner tie rod housing (2). Tighten the steering linkage inner tie rod to 150 Nm (111 lb ft). 5. Install the steering gear boot. Refer to Steering Gear Boot Replacement (HP2) (See: Steering Gear)Steering Gear Boot Replacement (Without HP2) (See: Steering Gear). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 12754 Tie Rod: Service and Repair Steering Linkage (Non-Rack & Pinion) Steering Linkage Inner Tie Rod Replacement Special Tools J 34028 Inner Tie Rod Wrench Removal Procedure 1. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 2. Remove the steering linkage outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Steering Linkage Outer Tie Rod Replacement). 3. Remove the steering linkage inner tie rod (1) from the relay rod using wrench J 34028 (2). Installation Procedure 1. Remove all traces of oil, grease, or other contaminants. 2. Clean the threads of the steering linkage inner tie rod with denatured alcohol or the equivalent and allow to dry. 3. Apply red LOCTITE(TM) threadlocker, GM P/N 12345493 (Canadian P/N 10953488) to the threads of the steering linkage inner tie rod. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the steering linkage inner tie rod (1) to the relay rod using wrench J 34028 (2) and tighten to 100 Nm (74 lb ft). 5. Install the steering linkage outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Steering Linkage Outer Tie Rod Replacement). 6. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 7. Adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Steering/Suspension - Ball Joint Availability Ball Joint: Technical Service Bulletins Steering/Suspension - Ball Joint Availability INFORMATION Bulletin No.: 07-03-08-009B Date: December 07, 2009 Subject: Two New Service Ball Joint Kits Available for Aluminum and Cast Iron Lower Control Arms - Kits NOT Interchangeable Models: 2007-2010 Cadillac Escalade, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Tahoe (1500 Series) 2007-2010 GMC Sierra, Yukon (1500 Series) Supercede: This bulletin is being revised to add the Silverado and Sierra models and update service information. Please discard Corporate Bulletin Number 07-03-08-009A (Section 03 Suspension). For the 2007-2010 model years, 1500 series light duty utility vehicles were built concurrently with either aluminum or cast iron front lower control arms. Each type of lower control arm requires a unique ball stud service part. Important Complete lower control arms should not be replaced for lower ball joint failures. All lower ball joints are now serviceable on aluminum and cast iron control arms for 1500 series pickup and utility models. The kit for cast iron control arms lower ball joints is P/N 19209396 and the aluminum lower ball joint kit is P/N 19256481. These kits are NOT interchangeable. There are new special tools that are released to service the lower ball joints on-vehicle (J-41805 and CH-49240). For the new lower ball joint service procedures, refer to Lower Control Arm Ball Joint Replacement in SI. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Page 12760 Ball Joint: Specifications Ball Joint Inspection (Lower Ball Joint) ......................................................................................................................... No More Than 0.50 mm (0.020 in) Ball Joint Inspection (Upper Ball Joint) ......................................................................................................................... No More Than 0.50 mm (0.020 in) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection (Lower Ball Joint) Ball Joint: Testing and Inspection Ball Joint Inspection (Lower Ball Joint) Lower Control Arm Ball Joint Inspection Special Tools J 8001 - Dial Indicator For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Front Suspension). Note: * The vehicle must rest on a level surface. * The vehicle must be stable. Do not rock the vehicle on the floor stands. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Clean and inspect the ball joint seal for cuts or tears. If the ball joint seal is damaged, replace the ball joint or the lower control arm as applicable for this vehicle. 3. Support the lower control arm with a floor stand as far outboard as possible and raise the suspension until the lower control arm moves 25 mm (1 in). 4. Install the J 8001 - dial indicator , or suitable dial indicator, to measure the vertical lash in the ball joint. Caution: Do not pry in such a way that the ball joint seal is contacted. Damage to the seal may result. 5. Lift the knuckle towards the lower control arm and record the dial indicator measurement. 6. If the dial indicator reading is more than 0.50 mm (0.020 in) , replace the ball joint or the lower control arm as applicable for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection (Lower Ball Joint) > Page 12763 Ball Joint: Testing and Inspection Upper Control Arm Ball Joint Inspection Upper Control Arm Ball Joint Inspection Special Tools J 8001 - Dial Indicator Set For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Front Suspension). Note: * The vehicle must rest on a level surface. * The vehicle must be stable. Do not rock the vehicle on the floor stands. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Clean and inspect the ball joint seal for cuts or tears. If the ball joint seal is damaged, replace the ball joint or upper control arm as applicable for this vehicle. 3. Support the lower control arm with a floor stand as far outboard as possible and raise the suspension until the lower control arm moves 25 mm (1 in). 4. Install the J 8001 - dial indicator , or suitable dial indicator, to measure the vertical lash in the ball joint. Caution: Do not pry in such a way that the ball joint seal is contacted. Damage to the seal may result. 5. Apply downward force to the upper control arm and zero the indicator. 6. Apply upward force to the upper control arm and check the dial indicator. Record the measurement 7. If the dial indicator reading is more than 0.50 mm (0.020 in) , replace the ball joint or the upper control arm as applicable for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 12764 Ball Joint: Service and Repair Lower Control Arm Ball Joint Replacement (1500 ) Special Tools * CH 41805 - Ball Joint Remover Install Kit * CH 49240 - Ball Joint Crimper and Install Kit For equivalent regional tools, refer to Special Tools (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Tools and Equipment). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the wheel drive shaft, if needed. Refer to Wheel Drive Shaft Replacement (2500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair). Note: Ensure that the knuckle is secured away from the lower control arm. 3. Remove the steering knuckle from the vehicle. Refer to Steering Knuckle Replacement (See: Rear Knuckle/Service and Repair). 4. Using a hammer chisel, remove the locking tabs (1) from the ball joint body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 12765 5. Position the CH 41805 - kit (1) on the lower control arm. 6. Using the CH 41805 - kit (1) and a shallow socket, remove the lower ball joint (2) from the control arm. Installation Procedure 1. Position the ball joint in the lower control arm. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 12766 Note: When using adapter CH-49240-2, the ensure that the teeth for the lock tabs are facing upward. 2. Using the and a shallow socket CH 41805 - kit (2), CH-49240-3 (1), CH-49240-1 (4) and the CH-49240-2 (2), install the ball joint. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 12767 3. Reverse the CH-49240-2 (3). 4. Using the CH 41805 - kit (2), CH-49240-3 (1), CH-49240-1 (4) and the CH-49240-2 (2), collapse the edge of the ball joint to create the lock tabs (5). Tighten the CH-49240-3 to 250 Nm (184 lb ft). Note: Repeat step 4 to ensure that all of the lock tabs are of the same depth and size. 5. Rotate the CH 41805 - kit (2) 180 degrees and repeat the process. 6. Install the wheel drive shaft, if needed. Refer to Wheel Drive Shaft Replacement (2500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair). 7. Install the steering knuckle in the vehicle. Refer to Steering Knuckle Replacement (See: Rear Knuckle/Service and Repair). 8. Install the lower ball joint stud nut and tighten to: * First Pass 50 Nm (37 lb ft) * Final Pass additional 95 degrees 9. Remove the supports and lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Steering/Suspension - Ball Joint Availability Control Arm: Technical Service Bulletins Steering/Suspension - Ball Joint Availability INFORMATION Bulletin No.: 07-03-08-009B Date: December 07, 2009 Subject: Two New Service Ball Joint Kits Available for Aluminum and Cast Iron Lower Control Arms - Kits NOT Interchangeable Models: 2007-2010 Cadillac Escalade, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Tahoe (1500 Series) 2007-2010 GMC Sierra, Yukon (1500 Series) Supercede: This bulletin is being revised to add the Silverado and Sierra models and update service information. Please discard Corporate Bulletin Number 07-03-08-009A (Section 03 Suspension). For the 2007-2010 model years, 1500 series light duty utility vehicles were built concurrently with either aluminum or cast iron front lower control arms. Each type of lower control arm requires a unique ball stud service part. Important Complete lower control arms should not be replaced for lower ball joint failures. All lower ball joints are now serviceable on aluminum and cast iron control arms for 1500 series pickup and utility models. The kit for cast iron control arms lower ball joints is P/N 19209396 and the aluminum lower ball joint kit is P/N 19256481. These kits are NOT interchangeable. There are new special tools that are released to service the lower ball joints on-vehicle (J-41805 and CH-49240). For the new lower ball joint service procedures, refer to Lower Control Arm Ball Joint Replacement in SI. Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement Control Arm: Service and Repair Upper Control Arm Replacement Upper Control Arm Replacement (1500) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 12774 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 12775 Control Arm: Service and Repair Lower Control Arm Replacement Lower Control Arm Replacement (1500) Special Tools * J 43631 - Ball Joint Separator * J 45851 - Ball Joint Separator Protector Adapters Removal Procedure Note: For vehicles equipped with the aluminum lower control arm, the ball joint is NOT service separately. If the ball joint in the aluminum lower control arm is found to have excessive wear and is damaged, replace the lower control arm as an assembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the stabilizer shaft link from the lower control arm. Refer to Stabilizer Shaft Link Replacement (2500, 3500) (See: Stabilizer Bar/Stabilizer Link/Service and Repair)Stabilizer Shaft Link Replacement (1500) (See: Stabilizer Bar/Stabilizer Link/Service and Repair). 4. Remove the wheel drive shaft, if equipped. Refer to Wheel Drive Shaft Replacement (2500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair). 5. Using mechanics wire or equivalent, support the knuckle assembly and upper control arm. 6. Remove and discard the lower ball joint retaining nut. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 12776 7. Remove the lower shock module bolts from the lower control arm. 8. Using the J 43631 and the J 45851 , remove the lower ball joint from the steering knuckle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 12777 9. Remove the lower control arm nuts (1) and washers (2). 10. Remove the control arm bolts (3). 11. Remove the control arm (4). Installation Procedure 1. Install the lower control arm (4). 2. Install the lower control arm bolts (3). 3. Install the washers (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the lower control arm retaining nuts (1) and tighten to 175 Nm (129 lb ft). 5. Install the lower ball joint in the steering knuckle. Note: There two types of nuts. One with a captured washer and one without. Use only the nut that is on the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 12778 6. Install the lower ball joint nut. * For those vehicles with the captured washer, tighten the nut to 125 Nm (92 lb ft). * For those vehicles without the captured washer, tighten the nut to 50 Nm plus 130 degrees (37 lb ft). 7. Install the lower shock absorber module mount bolts and tighten to 50 Nm (37 lb ft). 8. Remove the support for the steering knuckle and upper control arm. 9. Install the wheel drive shaft, if equipped. Refer to Wheel Drive Shaft Replacement (2500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair). 10. Install the stabilizer shaft link to the lower control arm. Refer to Stabilizer Shaft Link Replacement (2500, 3500) (See: Stabilizer Bar/Stabilizer Link/Service and Repair)Stabilizer Shaft Link Replacement (1500) (See: Stabilizer Bar/Stabilizer Link/Service and Repair). 11. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 12. Remove the support and lower the vehicle. 13. Align the front end. Refer to Wheel Alignment Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair Cross-Member: Service and Repair Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500, 2500 LD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair Steering Knuckle Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the wheel bearing and hub assembly. Refer to Front Wheel Hub, Bearing, and Seal Replacement (2500) ()Front Wheel Hub, Bearing, and Seal Replacement (1500) (See: Wheel Hub/Service and Repair). 4. Remove the outer tie rod end from the knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Steering/Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 5. Separate the upper control arm from the knuckle. Refer to Upper Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Upper Control Arm Replacement)Upper Control Arm Replacement (1500) (See: Control Arm/Service and Repair/Upper Control Arm Replacement). 6. Separate the lower control arm from the knuckle. Refer to Lower Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (2500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (1500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement). 7. Remove the knuckle from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 12785 1. Install the lower ball joint in the knuckle. Refer to Lower Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (2500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement )Lower Control Arm Replacement (1500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement). 2. Install upper ball joint in the knuckle. Refer to Upper Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Upper Control Arm Replacement)Upper Control Arm Replacement (1500) (See: Control Arm/Service and Repair/Upper Control Arm Replacement). 3. Install the outer tie rod end in the knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Steering/Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 4. Install the wheel bearing and hub assembly. Refer to Front Wheel Hub, Bearing, and Seal Replacement (2500) ()Front Wheel Hub, Bearing, and Seal Replacement (1500) (See: Wheel Hub/Service and Repair). 5. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 6. Remove the support and lower the vehicle. 7. Verify the wheel alignment. Refer to Wheel Alignment Specifications (See: Alignment/Specifications/Wheel Alignment Specifications). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12792 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12793 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12794 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12795 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12796 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12797 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair Stabilizer Bushing: Service and Repair Stabilizer Shaft Insulator Replacement (1500) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair Stabilizer Link: Service and Repair Stabilizer Shaft Link Replacement (1500) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Service and Repair Shackle: Service and Repair Rear Spring Shackle Replacement (1500 Series) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the leaf spring assembly from vehicle. Refer to Leaf Spring Replacement (See: Service and Repair/Rear Suspension Leaf Spring). 3. Remove the shackle nut and the bolt from the spring. Installation Procedure 1. Install the shackle to the spring. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the shackle nut and bolt to the spring. Tighten the shackle nuts to 95 Nm (70 lb ft). 3. Install the leaf spring assembly to the vehicle. Refer to Leaf Spring Replacement (See: Service and Repair/Rear Suspension Leaf Spring). 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information > Page 12813 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension Suspension Strut / Shock Absorber: Testing and Inspection Front Suspension Strut and Shock Absorber Inspection (Shock Absorber) Strut and Shock Absorber Inspection (Shock Absorber) Note: The shock absorber assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Note: A light film of oil on the top portion of the lower shock absorber tube is normal. DO NOT replace the shock absorber for this condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 12816 Condition 1 Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal, is not a shock absorber related problem. DO NOT replace the shock absorber, look for other external leaks. Condition 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 12817 Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal, is a NORMAL condition. DO NOT replace the shock absorber. Condition 3 Oil drip or trail down the lower shock tube and originating from the shaft seal, is an ABNORMAL condition. Replace the shock absorber. Condition 4 An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal (B), is an ABNORMAL condition. Replace the shock absorber. Refer to Shock Absorber Replacement (2500, 3500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement)Shock Absorber Replacement (1500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement ). Inspection 1. Verify the customer's concern is present. If the concern is present, continue to the next step. If the concern is not present, then the vehicle is operating normally. Note: The shock absorber assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 3. Visually inspect each of the shock absorbers for external fluid leaks. Refer to the following conditions 1, 2 , 3 , and 4 for visual inspection. * If conditions 1 or 2 are found, continue to step 4. * If conditions 3 or 4 are found, replace shock absorber. Refer to Shock Absorber Replacement (2500, 3500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement)Shock Absorber Replacement (1500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement). 4. If equipped with electronic suspension control system, ensure that the system is working properly. Refer to Diagnostic Starting Point - Electronic Suspension Control. 5. Use your hands in order to lift up and push down on each corner of the vehicle 3 times. Remove your hands from the vehicle. If the corner motion exceeds 2 cycles, replace the shock absorber. If the shock absorber does not exceed 2 cycles, NO repair is necessary. Strut and Shock Absorber Inspection (Coil Over Shock) Strut and Shock Absorber Inspection (Coil Over Shock) Note: The coil over shock assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Note: A light film of oil on the top portion of the shock absorber tube is normal. DO NOT replace the shock absorber for this condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 12818 Condition 1 Oil or fluid residue only on the bottom of the lower shock absorber tube or other coil over shock absorber and originating from the shaft seal, is not a shock absorber related problem. DO NOT replace the shock absorber, look for other external leaks. Condition 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 12819 Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal, is a NORMAL condition. DO NOT replace the shock absorber. Condition 3 Oil drip or trail down the shock absorber tube and originating from the shaft seal, is an ABNORMAL condition. Replace the shock absorber. Condition 4 An extreme wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal, is an ABNORMAL condition. Replace the shock absorber. Inspection 1. Verify the customer's concern is present. If the concern is present, continue to the next step. If the concern is not present, then the vehicle is operating normally. Note: The shock assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 3. Visually inspect each of the shock absorbers for external fluid leaks. Refer to the following conditions 1, 2, 3, and 4 for visual inspection. * If conditions 1 or 2 are found, continue to step 4. * If conditions 3 or 4 are found, replace shock absorber. Refer to Shock Absorber Replacement. 4. If equipped with electronic suspension control system, ensure that the system is working properly. Refer to Diagnostic Starting Point-Electronic Suspension Control. 5. Use your hands in order to lift up and push down on each corner of the vehicle 3 times. Remove your hands from the vehicle. If the corner motion exceeds 2 cycles, replace the shock absorber. If the shock absorber does not exceed 2 cycles, NO repair is necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 12820 Suspension Strut / Shock Absorber: Testing and Inspection Rear Suspension Strut and Shock Absorber Inspection (Shock Absorber) Note: The shock absorber assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Note: A light film of oil on the top portion of the lower shock absorber tube is normal. DO NOT replace the shock absorber for this condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 12821 Condition 1 Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal, is not a shock absorber related problem. DO NOT replace the shock absorber, look for other external leaks. Condition 2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 12822 Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal, is a NORMAL condition. DO NOT replace the shock absorber. Condition 3 Oil drip or trail down the lower shock tube and originating from the shaft seal, is an ABNORMAL condition. Replace the shock absorber. Condition 4 An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal (B), is an ABNORMAL condition. Replace the shock absorber. Refer to Shock Absorber Replacement (2500, 3500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement)Shock Absorber Replacement (1500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement ). Inspection 1. Verify the customer's concern is present. If the concern is present, continue to the next step. If the concern is not present, then the vehicle is operating normally. Note: The shock absorber assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 3. Visually inspect each of the shock absorbers for external fluid leaks. Refer to the following conditions 1, 2 , 3 , and 4 for visual inspection. * If conditions 1 or 2 are found, continue to step 4. * If conditions 3 or 4 are found, replace shock absorber. Refer to Shock Absorber Replacement (2500, 3500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement)Shock Absorber Replacement (1500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement). 4. If equipped with electronic suspension control system, ensure that the system is working properly. Refer to Diagnostic Starting Point - Electronic Suspension Control. 5. Use your hands in order to lift up and push down on each corner of the vehicle 3 times. Remove your hands from the vehicle. If the corner motion exceeds 2 cycles, replace the shock absorber. If the shock absorber does not exceed 2 cycles, NO repair is necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Front Suspension Shock Absorber Shock Absorber, Shock Absorber Component, or Spring Replacement Shock Absorber, Shock Absorber Component, or Spring Replacement Special Tools CH-48845 Spring Compressor Removal Procedure Warning Use only the CH-48845 Spring Compressor when servicing suspension components on this vehicle. Other tools may not be strong enough for the springs on this vehicle and you could be injured if you do not use Special Tool CH-48845. Failure to do so could result in serious personal injury. Note: Use only hand tools to perform the following service procedure. 1. Install the front shock absorber assembly in the CH-48845 . Note: For vehicles equipped with electronic suspension control, ensure that the upper retaining bracket of the CH-48845 is adjusted properly so that it DOES NOT damage the front suspension mount. 2. Position the shock absorber (2) in the upper retaining bracket of the CH-48845 (1) so the shock absorber will be centered. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 12825 3. Using the CH-48845 (1), compress the front spring (2). 4. Using the appropriate size wrench, hold the shock absorber shaft. Note: DO NOT re-use the shock absorber nut, discard and replace with new ONLY. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 12826 5. Using the appropriate tool, remove and discard the shock absorber nut (1). 6. Remove the front lower shock absorber (2) and the front spring lower insulator (1). 7. Remove the front suspension strut mount (1), front spring upper seat (2), front suspension strut bumper (3), front spring upper insulator (4), and the front suspension spring (5) from the spring compressor. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 12827 Note: The inboard strut mounting studs are spaced closer together than the outboard stud. The outboard stud should be facing toward the outside (closest to the technician proper alignment. 1. Assemble the front suspension strut mount (1), front spring upper seat (2), front suspension strut bumper (3), front spring upper insulator (4), and the front suspension spring (5) in the spring compressor. 2. Align the spring seat stop (3), the outboard stud (1), and the center of the lower strut mount (4). The notch in the spring seat (2) should be just to the right of the outboard stud. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 12828 Note: For vehicles equipped with electronic suspension control, ensure that the upper retaining bracket of the CH-48845 is adjusted properly so that it DOES NOT damage the front suspension mount. 3. Position the shock absorber (2) in the upper retaining bracket of the CH-48845 (1) so the shock absorber will be centered. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 12829 4. Using the CH-48845 (1), compress the front spring (2). 5. Using the appropriate size wrench, hold the shock absorber shaft. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 12830 6. Install the NEW shock absorber nut (1) and tighten. * For vehicles equipped with electronic suspension, tighten the shock absorber nut to 80 Nm (59 lb ft). * For vehicles equipped with electronic suspension, tighten the electrical connector to 20 Nm (15 lb ft). * For vehicles without electronic suspension, tighten the shock absorber nut to 60 Nm (44 lb ft). 7. Remove the shock absorber assembly from the spring compressor 8. Install the shock absorber in the vehicle. Refer to Shock Absorber and Spring Assembly Replacement (See: Shock Absorber and Spring Assembly Replacement). Shock Absorber Disposal Shock Absorber Disposal Warning Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Warning To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. 1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Shock Absorber and Spring Assembly Replacement Shock Absorber and Spring Assembly Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 12831 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 12832 Suspension Strut / Shock Absorber: Service and Repair Rear Suspension Shock Absorber Shock Absorber Replacement Shock Absorber Replacement (1500) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Support the rear axle. 3. Remove the upper shock absorber nut and the bolt. 4. Remove the lower shock absorber nut and the bolt. 5. Remove the shock absorber. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 12833 1. Install the shock absorber. 2. Install the upper shock absorber nut and bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the lower shock absorber nut and bolt. * Tighten the upper shock absorber bolts to 115 Nm (85 lb ft). * Tighten the lower shock absorber bolts to 115 Nm (85 lb ft). 4. Remove the support from the rear axle. 5. Remove the safety stands. 6. Lower the vehicle. Shock Absorber Disposal Shock Absorber Disposal Warning Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Warning To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 12834 1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > Customer Interest: > 10-03-08-002A > Nov > 10 > Suspension - Multiple Noises From Front Of Vehicle Suspension Travel Bumper: Customer Interest Suspension - Multiple Noises From Front Of Vehicle TECHNICAL Bulletin No.: 10-03-08-002A Date: November 03, 2010 Subject: Squeak/Creak/Rumble or Rattle Noise Coming from Front of Vehicle During Low Speed Maneuvers in Cold Ambient Temperatures (Enlarge Upper Inside Diameter (ID) of Strut Jounce Bumper) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado LD, Suburban LD, Tahoe 2007-2011 GMC Sierra LD, Sierra Denali, Yukon, Yukon XL LD, Yukon XL Denali Supercede: This bulletin is being revised to add the 2011 model year and clarify the text in the Subject, Condition, Cause and Correction. Please discard Corporate Bulletin Number 10-03-08-002 (Section - 03 Suspension). Condition Some customers may comment on a squeak, creak, rumble or rattle noise coming from the front of the vehicle or it may sound like it is coming through the front of the dash, during low speed maneuvers. The noise may be most noticeable in ambient temperatures of 0°C (32°F) or colder. The noise will most likely be heard during small to medium suspension travel such as in parking lot maneuvers, over small bumps, or when stopping. Cause This condition may be caused by the front strut jounce bumper inside diameter to the piston rod of the strut experiencing a slip/stick condition during certain cold ambient temperature conditions. Correction 1. Test drive the vehicle in the same range of ambient temperatures of 0°C (32°F) or colder and the same low speed maneuvers mentioned by the customer in order to verify the concern. 2. Using Chassis Ears, verify that the noise is most noticeable at the upper strut mount area. The concern may be on one or both sides of the vehicle. 3. By jouncing the vehicle, the noise or vibration can be isolated using a stethoscope, and may possibly be felt in the vicinity. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 5. Remove the LH and RH strut assemblies from the vehicle. Refer to Shock Absorber and Spring Assembly Replacement in SI. 6. Disassemble the coil spring and top mount assembly from each strut. Refer to Shock, Shock Component, and/or Spring Replacement in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > Customer Interest: > 10-03-08-002A > Nov > 10 > Suspension - Multiple Noises From Front Of Vehicle > Page 12843 7. Remove the jounce bumper (5) from the top mount assembly (3). 8. Secure the jounce bumper upright in a bench vise. Only clamp the lower portion of the bumper to allow the upper portion of the ID to remain at rest. Note A standard drill bit will not cut the ID of the jounce bumper. The jounce bumper will comply and stretch around the bit, then return after the drill is removed. 9. Prepare a single flute countersink bit or a bladed cutting bit, or equivalent, in a die grinder, Dremmel Tool, or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > Customer Interest: > 10-03-08-002A > Nov > 10 > Suspension - Multiple Noises From Front Of Vehicle > Page 12844 Note Do Not attempt to drill out the jounce bumper while attached to the strut top mount assembly. The bumper must be removed from the top mount assembly. Note Do Not attempt to drill out the jounce bumper from the lower end toward the upper end, as this could affect characteristics of the jounce bumper. 10. Enlarge the Upper ID (1) from the top side of the jounce bumper to the following dimensions: - Diameter of enlarged ID: 16 mm - Depth of enlarged ID: 15 mm 11. Ensure that the ID of the jounce bumper is as smooth as possible and free of loose material. If necessary, an Exacto knife, or equivalent, can be used to carefully trim the edge and remove any loose material. The photo above shows a jounce bumper with the enlarged upper ID (1) as compared to the original ID (2). Note Ensure that the jounce bumper is fully seated to the top mount assembly. 12. Install the jounce bumper to the top mount assembly. Ensure that the jounce bumper is secure to the top mount. 13. Assemble the coil spring and top mount to each strut. Refer to Shock, Shock Component, and/or Spring Replacement in SI. 14. Install the LH and RH strut assemblies to the vehicle. Refer to Shock Absorber and Spring Assembly Replacement in SI. 15. Move the vehicle outdoors to allow it to return to ambient temperature. 16. Test drive the vehicle under the same conditions to verify the repair. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > Customer Interest: > 10-03-08-002A > Nov > 10 > Suspension - Multiple Noises From Front Of Vehicle > Page 12845 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-03-08-002A > Nov > 10 > Suspension Multiple Noises From Front Of Vehicle Suspension Travel Bumper: All Technical Service Bulletins Suspension - Multiple Noises From Front Of Vehicle TECHNICAL Bulletin No.: 10-03-08-002A Date: November 03, 2010 Subject: Squeak/Creak/Rumble or Rattle Noise Coming from Front of Vehicle During Low Speed Maneuvers in Cold Ambient Temperatures (Enlarge Upper Inside Diameter (ID) of Strut Jounce Bumper) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado LD, Suburban LD, Tahoe 2007-2011 GMC Sierra LD, Sierra Denali, Yukon, Yukon XL LD, Yukon XL Denali Supercede: This bulletin is being revised to add the 2011 model year and clarify the text in the Subject, Condition, Cause and Correction. Please discard Corporate Bulletin Number 10-03-08-002 (Section - 03 Suspension). Condition Some customers may comment on a squeak, creak, rumble or rattle noise coming from the front of the vehicle or it may sound like it is coming through the front of the dash, during low speed maneuvers. The noise may be most noticeable in ambient temperatures of 0°C (32°F) or colder. The noise will most likely be heard during small to medium suspension travel such as in parking lot maneuvers, over small bumps, or when stopping. Cause This condition may be caused by the front strut jounce bumper inside diameter to the piston rod of the strut experiencing a slip/stick condition during certain cold ambient temperature conditions. Correction 1. Test drive the vehicle in the same range of ambient temperatures of 0°C (32°F) or colder and the same low speed maneuvers mentioned by the customer in order to verify the concern. 2. Using Chassis Ears, verify that the noise is most noticeable at the upper strut mount area. The concern may be on one or both sides of the vehicle. 3. By jouncing the vehicle, the noise or vibration can be isolated using a stethoscope, and may possibly be felt in the vicinity. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 5. Remove the LH and RH strut assemblies from the vehicle. Refer to Shock Absorber and Spring Assembly Replacement in SI. 6. Disassemble the coil spring and top mount assembly from each strut. Refer to Shock, Shock Component, and/or Spring Replacement in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-03-08-002A > Nov > 10 > Suspension Multiple Noises From Front Of Vehicle > Page 12851 7. Remove the jounce bumper (5) from the top mount assembly (3). 8. Secure the jounce bumper upright in a bench vise. Only clamp the lower portion of the bumper to allow the upper portion of the ID to remain at rest. Note A standard drill bit will not cut the ID of the jounce bumper. The jounce bumper will comply and stretch around the bit, then return after the drill is removed. 9. Prepare a single flute countersink bit or a bladed cutting bit, or equivalent, in a die grinder, Dremmel Tool, or equivalent. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-03-08-002A > Nov > 10 > Suspension Multiple Noises From Front Of Vehicle > Page 12852 Note Do Not attempt to drill out the jounce bumper while attached to the strut top mount assembly. The bumper must be removed from the top mount assembly. Note Do Not attempt to drill out the jounce bumper from the lower end toward the upper end, as this could affect characteristics of the jounce bumper. 10. Enlarge the Upper ID (1) from the top side of the jounce bumper to the following dimensions: - Diameter of enlarged ID: 16 mm - Depth of enlarged ID: 15 mm 11. Ensure that the ID of the jounce bumper is as smooth as possible and free of loose material. If necessary, an Exacto knife, or equivalent, can be used to carefully trim the edge and remove any loose material. The photo above shows a jounce bumper with the enlarged upper ID (1) as compared to the original ID (2). Note Ensure that the jounce bumper is fully seated to the top mount assembly. 12. Install the jounce bumper to the top mount assembly. Ensure that the jounce bumper is secure to the top mount. 13. Assemble the coil spring and top mount to each strut. Refer to Shock, Shock Component, and/or Spring Replacement in SI. 14. Install the LH and RH strut assemblies to the vehicle. Refer to Shock Absorber and Spring Assembly Replacement in SI. 15. Move the vehicle outdoors to allow it to return to ambient temperature. 16. Test drive the vehicle under the same conditions to verify the repair. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-03-08-002A > Nov > 10 > Suspension Multiple Noises From Front Of Vehicle > Page 12853 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Travel Bumper: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: All Technical Service Bulletins Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Travel Bumper: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 12859 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Travel Bumper: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 12860 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Travel Bumper: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 12861 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Travel Bumper: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 12867 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Travel Bumper: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 12868 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Travel Bumper: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 12869 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension Suspension Travel Bumper: Service and Repair Front Suspension Jounce Bumper Replacement (2500 Series) Removal Procedure Note: The following service procedure is for 2500 series vehicles. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the nut from the jounce bumper stud. 4. Remove the jounce bumper. Installation Procedure 1. Install the jounce bumper. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the nut to the jounce bumper stud and tighten to 30 Nm (22 lb ft). 3. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension > Page 12872 Suspension Travel Bumper: Service and Repair Rear Suspension Jounce Bumper Replacement (1500) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar and Support Assembly Replacement (Bushing Style) Torsion Bar: Service and Repair Torsion Bar and Support Assembly Replacement (Bushing Style) Torsion Bar and Support Assembly Replacement (Bushing Style) Special Tools J 36202 Torsion Bar Unloading/Loading Tool Removal Procedure Note: When lifting the vehicle to service the torsion bars or related components, DO NOT lift the vehicle by the front suspension. Use the appropriate hoist to lift the vehicle by the frame. Caution: Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Install the J 36202 to the adjustment arm and the crossmember. 3. Using the J 36202 , increase the tension on the adjustment arm until the load is removed from the adjustment bolt and the adjuster nut. Note: Mark the adjustment bolt and count the number of times that is required to remove the adjustment bolt. 4. Remove the adjustment bolt (3) and the adjust nut (4) from the crossmember (1). 5. Remove the J 36202 , allowing the torsion bar to unload. 6. Remove the adjustment arm (2) by sliding the torsion bar forward. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar and Support Assembly Replacement (Bushing Style) > Page 12877 7. Remove the torsion bar crossmember bolt (4) from the weld nut (1). 8. Remove the crossmember (2) from the crossmember mount (3). 9. Remove the torsion bar from the crossmember. Note: The left and right torsion bars are different and are not interchangeable. 10. Remove the torsion bars from the vehicle. Installation Procedure 1. Position the torsion bar in the lower control arm. 2. Install the torsion bar in the crossmember (2) on the crossmember mount (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the torsion bar crossmember bolt (4) in the weld nut (1) and tighten to 110 Nm (81 lb ft).. 4. Install the adjustment arm (2) in the crossmember (1). 5. Install the adjuster bolt (3) and the adjuster nut (4). 6. Install the torsion bar into the adjustment arm until the torsion bar is fully seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar and Support Assembly Replacement (Bushing Style) > Page 12878 7. Install the J 36202 to the adjustment arm and the crossmember. 8. Using the J 36202 , increase the tension on the adjustment arm to load the torsion bar. 9. Turn the adjuster bolt the same amount of turns as it took to remove it. 10. Remove the J 36202 from the crossmember. 11. Remove the safety stands and lower the vehicle. 12. Measure the Z height. Refer to Trim Height Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar and Support Assembly Replacement (Bushing Style) > Page 12879 Torsion Bar: Service and Repair Torsion Bar and Support Assembly Replacement (Link Style) Torsion Bar and Support Assembly Replacement (Link Style) Special Tools J 36202 Torsion Bar Unloading/Loading Tool Removal Procedure Note: When lifting the vehicle to service the torsion bars or related components, DO NOT lift the vehicle by the front suspension. Use the appropriate hoist and lift the vehicle by the frame. Caution: Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Install the J 36202 to the adjustment arm and the support assembly. 3. Using the J 36202 , increase the tension on the adjustment arm until the load is removed from the adjustment bolt and the adjuster nut. Note: Create a reference point for the adjustment bolt to the support. Count the number of times that is required to remove the adjustment bolt. 4. Remove the adjustment bolt (3) and the adjuster nut (4) from the support assembly (1). 5. Remove the J 36202 , allowing the torsion bar to unload. 6. Remove the adjustment arm (2) by sliding the torsion bar forward. 7. Remove the adjustment arm (2) from the support assembly (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar and Support Assembly Replacement (Bushing Style) > Page 12880 8. Remove the upper link mounting bolt (1) and nut (2) from the link (3). 9. Remove the torsion bar support assembly (4). Note: The left and right torsion bars are different and are not interchangeable 10. Remove the torsion bar from the vehicle. Installation Procedure 1. Position the torsion bar in the lower control arm. 2. Install the torsion bar in the support assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the upper link mounting nut (2) and the bolt (1) in the link (3). Tighten the nut to 95 Nm (70 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar and Support Assembly Replacement (Bushing Style) > Page 12881 4. Install the adjustment arm (2) in the support assembly (1). 5. Install the adjuster bolt (3) and the adjustment nut (4). 6. Slide the torsion bar rearward until the torsion bar is fully seated in the adjustment arm. 7. Install the J 36202 on the adjustment arm and the support assembly. 8. Using the J 36202 , increase the tension on the adjustment arm in order to load the torsion bar. 9. Align the reference marks, turn the adjuster bolt the same amount of turns as it took to remove it. 10. Remove the J 36202 from the support assembly. 11. Remove the safety stand and lower the vehicle. 12. Measure the Z height. Refer to Trim Height Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar and Support Assembly Replacement (Bushing Style) > Page 12882 Torsion Bar: Service and Repair Torsion Bars Bushing Replacement Torsion Bars Bushing Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 12886 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Drive Shaft Nut ......................................................................................................................... .................................................... 240 Nm (177 lb ft) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle contents. For lifting the vehicle, various lift points are recommended. Before you begin any lifting procedure, place the vehicle on a clean, hard, level surface. Verify that all the lifting equipment meets weight standards and is in good working order. Verify that all of the vehicle loads are equally distributed and secure. If you are only supporting the vehicle at the frame side rails, verify that the lifting equipment does not put too much stress on, or weaken, the frame side rails. During hoisting, do NOT damage the fuel tanks, the exhaust system, or the underbody. 1 - Lower Control Arm Contact Points 2 - Front Frame Contact Points 3 - Rear Frame Contact Points 4 - Rear Axle Contact Points Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 12895 5 - Differential Contact Points Frame Contact Hoist Front Hoist Pads Note: The front hoist pads must not contact the rocker panels, the front fenders, or the floor pan. Position the front hoist pads under the front frame between the lower control arm and the frame pad. Rear Hoist Pads Note: The rear hoist pads must not contact the body rocker panels or the floor pan. Position the rear hoist pads under the rear spring, just behind the hanger Suspension Contact Hoist Front Lift Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 12896 Position the front lift under the outer edge of the front suspension lower control arms. Rear Lift Position the rear lift under the axle housing tubes on each side of the differential. Do not damage the stabilizer bar. Jacking When you are lifting a vehicle with a vehicle jack or a floor jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Under the Frame Rails Note: The floor jack pad must not contact rocker panel or the floor pan. Position the floor jack pad under the frame rail pad. Under the Rear Differential Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 12897 Position the floor jack pad under the center of the rear axle differential. Do not damage the establisher bar. Under the Rear Spring Hanger Position the jack under the rear spring hanger. Jack Stands When you support the vehicle with jack stands, place the jack stands under the frame, the front suspension crossmember, or the rear axle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Module: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Module: > 10-03-16-001 > Jul > 10 > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tire Pressure Module: > 10-03-16-001 > Jul > 10 > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Customer Interest for Tire Pressure Monitor Receiver / Transponder: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Monitor Receiver / Transponder: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 12939 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 12940 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 12943 Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 12944 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 12945 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in). Note: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Note: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 12946 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 12952 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 12953 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 12954 Customer TPMS Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 12955 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 12956 Frequently Asked Questions Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Module: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Module: > 10-03-16-001 > Jul > 10 > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tire Pressure Module: > 10-03-16-001 > Jul > 10 > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Customer Interest for Tire Pressure Monitor Receiver / Transponder: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tire Pressure Monitor Receiver / Transponder: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 12996 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 12997 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 13000 Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 13001 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 13002 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in). Note: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Note: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 13003 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair Spare Tire: Service and Repair Spare Wheel Hoist Replacement Tire Hoist Secondary Latch Mechanism Note: If the spare tire hoist has been fully raised without a spare tire in place, the secondary latch mechanism may have become engaged. If this has occurred the hoist will not lower and the following steps will need to be followed: 1. Rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable (1) is exposed. 2. While holding the latch pin (3), fully depress the latch button (2) and release the secondary latch from the hoist assembly. Some side-to-side and/or up-and-down movement may be necessary to disengage the latch mechanism. 3. Continue rotating the hoist shaft counterclockwise in order to lower the hoist the rest of the way. 4. If this does not release the secondary latch, the spare tire hoist will need to be replaced. See the following procedure. Removal Procedure 1. If the vehicle is equipped with a spare tire stowage lock cylinder, open the spare tire lock cover on the bumper and using the ignition key, remove the lock. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 13008 Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 2. Rotate the hoist shaft counterclockwise in order to lower the spare tire to the ground. Continue to rotate the shaft until the spare tire can be pulled out from under the vehicle and removed. If the spare tire does not lower to the ground, the secondary latch is engaged causing the tire not to lower. 3. If the secondary latch is engaged and the cable end is visible, perform the following procedure: 1. Tighten the cable by rotating the hoist shaft clockwise until you hear 2 clicks or feel it skip twice. You cannot overtighten the cable. 2. Loosen the cable by rotating the hoist shaft counterclockwise 3 or 4 turns. 3. If the spare tire can be lowered, repeat steps 1 and 2 to see if the spare tire can be removed. 4. If the spare tire cannot be lowered, rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable is exposed. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 6. Place a transmission jack, or equivalent, under the spare tire. 7. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 8. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 9. Lower the tire. If the spare tire is hanging by the cable, rotate the hoist shaft counterclockwise until the tire is low enough to remove. 4. If the secondary latch is engaged and the cable end is NOT visible, perform the following procedure: 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Place a transmission jack, or equivalent, under the spare tire. 3. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 4. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 5. Lower the tire and remove it from the jack. 5. Raise and support the vehicle if it is not already raised. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 6. Depress the tabs, remove the guide shaft from the hoist collar, and slide the shaft toward the bumper. 7. Remove the collar from the hoist. 8. Remove the bolt. 9. Remove the hoist from the bracket. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 13009 10. Remove the spare tire hoist shaft guide from the bumper. Installation Procedure 1. Install the spare tire hoist shaft guide to the bumper. 2. Install the hoist to the crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolt and tighten to 40 Nm (30 lb ft). 4. Install the collar to the hoist. 5. Install the shaft to the hoist. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 13010 6. Install the spare tire to the hoist. Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 7. Rotate the hoist shaft clockwise until the spare tire is in position and the hoist clicks 2 times or it skips twice. You cannot overtighten the cable. 8. Remove the safety stands. 9. Lower the vehicle. 10. Install the spare tire stowage lock cylinder. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheels: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 13019 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 13024 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 13025 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 13026 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 13031 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 13036 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 13037 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 13038 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 13044 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 13045 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 13046 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-03-10-012D > Apr > 11 > Tires/Wheels Rattle Noise from Wheel Or Hub Cap Wheels: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-03-10-012D > Apr > 11 > Tires/Wheels Rattle Noise from Wheel Or Hub Cap > Page 13051 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 13056 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 13061 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 13062 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 13067 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 13068 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 13069 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 13074 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 13079 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 13080 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 13081 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 13087 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 13088 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 13089 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 13094 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 13099 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 13100 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Replacement Wheels Description Wheels: Description and Operation Replacement Wheels Description Replacement Wheels Description Replace the wheel if any of the following conditions exist: * The wheel exhibits excessive runout. * The wheel is bent. * The wheel is cracked. * The wheel is severely rusted. * The wheel is severely corroded. Note: Air leaks caused by porosity on aluminum wheels are repairable. * The wheel leaks air. Warning If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Caution: The use of non-GM original equipment wheels may cause: * Damage to the wheel bearing, the wheel fasteners and the wheel * Tire damage caused by the modified clearance to the adjacent vehicle components * Adverse vehicle steering stability caused by the modified scrub radius * Damage to the vehicle caused by the modified ground clearance * Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: * The wheel has elongated bolt holes. * The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Replacement Wheels Description > Page 13103 Wheels: Description and Operation Steel Wheel Repair Description Steel Wheel Repair Description Caution: Do not heat wheels in an attempt to soften them for straightening or repair damage from striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and uncontrolled heating from welding affects the properties of the material. Caution: The use of tubes in tubeless tires is not a recommended repair due to the fact that speed ratings are greatly reduced. You can repair porosity in aluminum wheels. If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 13104 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Guidelines Warning To avoid personal injury when exposed to plastic media blast, hand and/or lathe sanding dust, primer, color coat, and clearcoat, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs and protective gloves and clothing. Evaluating Damage Note: * Inspect the wheel for corrosion, scrapes, gouges, etc. Damage MUST NOT be deeper than what can be sanded or polished off. * Inspect the wheel for cracks. If cracks are found, discard the wheel. * ALL wheels with bent rim flanges must not be repaired or refinished. * The re-machining and the re-clear coating of aluminum wheels is not recommended in the dealer environment due to concerns of repair durability. * Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Aluminum Wheel Refinishing General Recommendations/Options * Painted aluminum wheels use a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. (See option number 1). * If the clearcoat is damaged, it is possible to refinish with clearcoat only, however, the required refinishing process cannot be performed in the dealer environment. Refer to Refinishers Responsibility (Repair option number 2). * Re-plating of chrome-plated aluminum wheels is not recommended. Repair Option Number 1 Material Required/Information Resources * The Paint Manufacturer's Color Book * Refer to the latest GM Approved Refinish Materials Booklet (GM 4901 MD-2005) for specific products for aluminum refinishing. * To access the booklet, go to www.gmgoodwrench.com. Click on GM Collision Parts. Click on GM Technical Repair Information, select Paint Shop. * A Color Compatibility chart is also at this site defining what colors are used on what models. Note: Chemical strippers are not recommended. * Refer to specific Paint Manufacturers for refinish procedures and process pertaining to "Aluminum Refinishing". The procedure requires the wheel surface to be plastic media blasted to remove old paint or clearcoat. General Color Selection * If the wheels being painted were previously clearcoated aluminum, and a painted aluminum look is desired, using Corsican Silver WAEQ9283 for a fine "aluminum-like" look, or Sparkle Silver WA9967 for a very bright look. Body color is another option to the customer that may also be used. * Some specific colors may be recommended on certain models. * If painting wheels that were previously clearcoated aluminum, it is recommended that all 4 wheels and their center caps be refinished to maintain color uniformity. General Refinishing Procedures - Removal 1. Remove the wheels from the vehicle. The tires may remain mounted on the wheels. 2. Remove the balance weights and mark their locations on the tire. 3. Remove excess grease, etc. from the wheels with wax and grease remover. 4. Have the wheels plastic media blasted to remove the clearcoat. Note: MASK OFF ALL MOUNTING SURFACES, whenever a wheel is refinished. The mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. 5. Clean and mask and paint the wheels. General Refinishing Procedures - Installation 1. Unmask the wheels. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 13105 2. Clean all wheel mounting surface of any corrosion, overspray, or dirt. Note: When re-balancing a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. 3. Install NEW coated balance weights at marked locations. Note: Use a torque stick on an impact wrench, or a torque wrench to consistently and uniformly fasten the wheel to the specified torque for the vehicle. The star pattern must be followed. 4. Install wheels on vehicle. Repair Option Number 2 - Outside Companies * Some outside companies are offering wheel refinishing services. One such company, Transwheel Corporation (800-892-3733), provides this service with GM guidelines. Other companies may also exist. * Any process that re-machines or otherwise remanufactures the wheel should not be used. * The wheel ID must be recorded and follow the wheel throughout the process to assure that the same wheel is returned. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is longer. * Paint and/or clearcoat must not be present on the following surfaces, the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. * A refinishers responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 13109 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Drive Shaft Nut ......................................................................................................................... .................................................... 240 Nm (177 lb ft) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 13122 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 13128 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 13129 Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ..................................................... 190 Nm (140 lb ft) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 13130 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: * The wheel/nut has the word Metric stamped on the face. * The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. * M = Metric * 12 = Diameter in millimeters * 1.5 = Millimeters gap per thread Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the brake rotor. Refer to Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JD9, JF3, JF7, JG4))Front Brake Rotor Replacement (JH6, JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JH6, JH7)). 4. Use the J 43631 to press the stud from the wheel bearing/hub. Installation Procedure 1. Install a new stud. Use washers and a wheel nut and pull the new stud into the hub. 2. Install the brake rotor. Refer to Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JD9, JF3, JF7, JG4))Front Brake Rotor Replacement (JH6, JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JH6, JH7)). 3. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 13133 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement Special Tools J 43631 - Ball Joint Remover For equivalent regional tools, refer to Special Tools (See: Suspension/Tools and Equipment/Rear Suspension) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 4. Remove the rear brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 5. Using the J 43631 - remover , remove wheel stud from the rear axle shaft. 6. For those vehicles equipped with RPO codes JH6 or JH7, remove the rear axle hub assembly. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 13134 1. Position the wheel stud in the rear axle shaft. 2. Using washers and a wheel nut, tighten the wheel nut until the wheel stud is firmly seated in the rear axle shaft. 3. Remove the wheel nut and the washers. 4. Install the rear axle hub assembly, if removed. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). 5. Install the brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 6. Install the rear brake drum. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 7. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 8. Remove the supports and lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams Air Door Actuator / Motor: Diagrams Component Connector End Views Air Temperature Actuator - Left (CJ2) Air Temperature Actuator - Right (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 13140 Air Temperature Actuator (C67 or C42) Recirculation Actuator (C67 or CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 13141 Mode Actuator (C67, C42 or CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic Air Door Actuator / Motor: Service and Repair HVAC - Automatic Air Inlet Valve Actuator Replacement Air Inlet Valve Actuator Replacement Mode Valve Actuator Replacement Mode Valve Actuator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13144 Temperature Valve Actuator Replacement - Right Side Temperature Valve Actuator Replacement - Right Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13145 Temperature Valve Actuator Replacement - Left Side Temperature Valve Actuator Replacement - Left Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13146 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13147 Air Door Actuator / Motor: Service and Repair HVAC - Manual Air Inlet Valve Actuator Replacement Air Inlet Valve Actuator Replacement Mode Valve Actuator Replacement Mode Valve Actuator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13148 Temperature Valve Actuator Replacement Temperature Valve Actuator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13149 Temperature Valve Actuator Replacement - Left Side Temperature Valve Actuator Replacement - Left Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13150 Temperature Valve Actuator Replacement - Right Side Temperature Valve Actuator Replacement - Right Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement Air Duct: Service and Repair Air Distributor Duct Replacement Air Distributor Duct Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 13155 Air Duct: Service and Repair Floor Air Outlet Duct Replacement - Left Side Floor Air Outlet Duct Replacement - Left Side Removal Procedure 1. Remove the push pin from the left floor air outlet duct (3). 2. Remove the left floor duct (3) from the right floor air outlet duct (2). Installation Procedure 1. Install the left floor air outlet duct (3) to the right floor air outlet duct (2). 2. Install the push pin to the left floor air outlet duct (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 13156 Air Duct: Service and Repair Floor Air Outlet Duct Replacement - Right Side Floor Air Outlet Duct Replacement - Right Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 13157 Air Duct: Service and Repair Air Inlet Assembly Replacement Air Inlet Assembly Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement Air Register: Service and Repair Side Window Air Outlet Replacement Side Window Air Outlet Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13162 Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13163 Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13164 Air Register: Service and Repair Instrument Panel Center Air Outlet Replacement (without RPO SLT) Instrument Panel Center Air Outlet Replacement (without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13165 Air Register: Service and Repair Side Window Air Outlet Replacement Side Window Air Outlet Replacement Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13166 Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13167 Instrument Panel Center Air Outlet Replacement (without RPO SLT) Instrument Panel Center Air Outlet Replacement (without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13168 Instrument Panel Center Air Outlet Replacement (With RPO SLT) Instrument Panel Center Air Outlet Replacement (With RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13169 Instrument Panel Outer Air Outlet Replacement - Right Side (Without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Right Side (Without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13170 Instrument Panel Outer Air Outlet Replacement - Right Side (With RPO SLT) Instrument Panel Outer Air Outlet Replacement - Right Side (With RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13171 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views Ambient Air Temperature Sensor (CJ2 or C67) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 13175 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13180 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13181 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13182 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13183 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13184 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13185 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13186 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13187 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13188 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13189 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13190 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13191 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13192 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 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and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13198 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13199 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13200 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13201 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13202 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13203 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13204 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13205 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13206 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13207 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13208 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13209 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13210 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13211 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13212 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13213 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13214 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13215 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13216 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13217 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13218 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13219 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13220 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13221 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13222 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13223 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13224 Blower Motor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13225 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13226 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13227 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13228 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13229 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13230 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13231 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13232 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13233 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13234 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13235 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13236 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13237 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13238 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13239 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13240 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13241 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13242 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13243 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13244 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13245 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13246 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13247 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13248 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13249 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13250 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13251 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13252 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13253 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13254 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13255 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13256 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13257 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13258 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13259 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13260 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13261 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13262 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13263 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13264 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13265 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13266 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13267 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13268 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13269 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13270 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13271 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13272 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13273 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13274 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13275 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13276 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13277 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13278 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13279 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13280 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13281 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13282 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13283 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13284 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13285 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13286 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13287 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13288 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13289 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13290 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13291 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13292 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13293 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13294 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13295 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13296 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13297 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13298 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13299 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13300 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13301 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13302 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13303 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13304 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13305 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13306 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13307 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13308 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13309 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13310 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13311 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13312 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13313 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13314 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13315 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13316 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13317 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13318 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13319 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13320 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13321 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13322 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13323 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13324 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13325 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13326 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13327 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13328 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13329 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13330 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13331 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13332 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13333 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13334 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13335 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13336 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13337 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13338 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13339 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13340 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13341 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13342 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13343 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13344 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13345 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13346 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13347 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13348 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13349 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13350 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13351 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13352 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13353 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13354 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13355 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13356 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13357 Blower Motor: Connector Views Component Connector End Views Blower Motor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 13358 Blower Motor: Service and Repair Blower Motor Replacement Removal Procedure 1. If equipped, remove the sound insulator panel. Refer to Instrument Panel Insulator Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement (With RPO SLT))Instrument Panel Insulator Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement (Without RPO SLT)). 2. Remove the blower motor insulating cover screws. 3. Disconnect the electrical connector from the blower motor. 4. Remove the blower motor insulating cover. 5. Pull the retaining tab down while turning the blower motor counterclockwise in order to disengage the blower motor from the heater/ventilation module. 6. Remove the blower motor. Installation Procedure 1. Install the blower motor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 13359 2. Install the blower motor to the heater/ventilation module. Turn the blower assembly clockwise until the retaining tab locks into place. 3. Install the blower motor insulating cover. 4. Connect the electrical connector to the blower motor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the blower motor insulating cover screws and tighten to 1.6 Nm (14 lb in). 6. If equipped, install the sound insulator panel. Refer to Instrument Panel Insulator Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement (With RPO SLT))Instrument Panel Insulator Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement (Without RPO SLT)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement Removal Procedure 1. Remove the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 2. Remove the left center pillar assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair/Roof Rail Rear Assist Handle Replacement). 3. Remove the center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Garnish Molding Replacement). 4. Remove the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair). 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. Installation Procedure 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Page 13363 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair). 5. Install the left center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Garnish Molding Replacement). 6. Install the left center assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair/Roof Rail Rear Assist Handle Replacement). 7. Install the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48))Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48))Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Regular Cab)) 2. Remove the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)) 3. Pull back carpeting on the rear wall of the cab exposing the pressure relief valve. 4. Press on the retaining tab on the top downward to release the valve from the cab back panel. 5. Remove the pressure relief valve from the vehicle. Installation Procedure 1. Align the pressure relief valve into the opening of the rear cab. 2. Press the pressure relief valve into the cab back panel until the locking tabs are fully seated. 3. Realign carpeting on the rear wall of the cab to lay flat. 4. Install the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)) 5. Install the rear window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48))Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48))Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Regular Cab)) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Pulley To Drive Plate Air Gap .............................................................................................................................................. 0.35-0.65 mm (0.014-0.026 in) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 13371 Compressor Clutch: Diagrams Component Connector End Views A/C Compressor Clutch (C67) A/C Compressor Clutch (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 13372 Compressor Clutch: Adjustments Air Conditioning Clutch Drive Plate Adjustment 1. Install the clutch plate assembly. Note: Ensure the drive plate does not drag against the pulley when the pulley is rotated. 2. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.35-0.65 mm (0.014-0.026 in) air gap. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the clutch plate retaining bolt and tighten to 18 Nm (13 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair Compressor Clutch Hub: Service and Repair Compressor Clutch Plate/Hub Assembly Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Page 13376 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 13380 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 13381 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 13382 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 13383 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 13384 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 13385 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 13386 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair Condenser HVAC: Service and Repair Air Conditioning Condenser Replacement (Gas) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Service and Repair). 2. Remove the fascia. 3. Remove radiator support bolts (1). Access the bolts from the rear of the upper radiator support. Refer to Radiator Support Replacement (See: Body and Frame/Radiator Support/Service and Repair/Radiator Support Replacement). 4. Remove radiator support bracket bolts (1). 5. Remove the compressor discharge hose assembly bolt from the condenser. 6. Disconnect the compressor discharge hose assembly from the condenser. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 13390 7. Remove the evaporator tube nut from the condenser. 8. Disconnect the evaporator tube from the condenser. 9. Remove the insulator retainer bolts and the upper insulator retainers. 10. Remove the condenser from the vehicle. Installation Procedure Note: If replacing the condenser, add the refrigerant oil to the condenser. Refer to Refrigerant System Specifications (Non-HP2) (See: Refrigerant Oil/Specifications) for system capacity information. 1. Install the condenser to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the upper insulator retainers and the insulator retainer bolts and tighten to 2.4 Nm (21 lb in). 3. Connect the evaporator tube to the condenser using new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 4. Install the evaporator tube nut to the condenser and tighten to 16 Nm (12 lb ft). 5. Connect the compressor discharge hose to the condenser using new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 6. Install the compressor discharge hose nut to the condenser and tighten to 16 Nm (12 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 13391 7. Install the lower bolts to the hood latch support bracket and tighten to 9 Nm (80 lb in). 8. Install the radiator support. Access the bolts (1) from the rear of the upper radiator support. Refer to Radiator Support Replacement (See: Body and Frame/Radiator Support/Service and Repair/Radiator Support Replacement). Tighten the nut to 16 Nm (12 lb ft). 9. Install radiator support bracket bolts (1). 10. Install the fascia. 11. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Service and Repair). 12. Leak test the fittings of the component using the J 39400-A . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 11-01-38-001 > Feb > 11 > A/C - Excessive Cabin Moisture/Reduced Window Clearing Control Module HVAC: Customer Interest A/C - Excessive Cabin Moisture/Reduced Window Clearing TECHNICAL Bulletin No.: 11-01-38-001 Date: February 28, 2011 Subject: Excessive Cabin Moisture / Reduced Window Clearing (Reprogram HVAC System Control Module) Models: 2010-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL All with RPO CJ3 or C67 (Manual Air Conditioning) Condition In rare cases, some customers may comment on excessive cabin moisture or difficulty keeping the windows clear in low ambient temperatures. Cause This concern may be caused by the recirculation door being in the recirculation position while the mode is set to a floor through defrost position. Correction Important DO NOT replace the HVAC control module for this concern. Revised software has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest software currently available in TIS2WEB. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 10-01-38-001 > Mar > 10 > A/C - Reduced Windshield Clearing/Defrost Control Module HVAC: Customer Interest A/C - Reduced Windshield Clearing/Defrost TECHNICAL Bulletin No.: 10-01-38-001 Date: March 02, 2010 Subject: Reduced Windshield Clearing\Defrost at Low Ambient Temperatures (Reprogram HVAC Control Module) Models: 2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with HVAC System RPOs C42, C67 or CJ3 All Built Prior to February 17, 2010 Condition In rare cases, some customers may comment that the HVAC system has reduced defrost or added difficulty keeping the windshield clear in low ambient temperatures. Cause This condition may be caused by the airflow calibrations which can contribute to the above condition. Calibration changes at the start of the 2010 model year may not meet some customers' expectations. Testing has confirmed that defrost levels will meet requirements. Correction Important DO NOT replace the HVAC Control Module for this concern. Reprogram the HVAC Control Module with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest calibrations available on TIS2WEB. Refer to HVAC System Control Module Programming and Setup in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11-01-38-001 > Feb > 11 > A/C Excessive Cabin Moisture/Reduced Window Clearing Control Module HVAC: All Technical Service Bulletins A/C - Excessive Cabin Moisture/Reduced Window Clearing TECHNICAL Bulletin No.: 11-01-38-001 Date: February 28, 2011 Subject: Excessive Cabin Moisture / Reduced Window Clearing (Reprogram HVAC System Control Module) Models: 2010-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL All with RPO CJ3 or C67 (Manual Air Conditioning) Condition In rare cases, some customers may comment on excessive cabin moisture or difficulty keeping the windows clear in low ambient temperatures. Cause This concern may be caused by the recirculation door being in the recirculation position while the mode is set to a floor through defrost position. Correction Important DO NOT replace the HVAC control module for this concern. Revised software has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest software currently available in TIS2WEB. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 10-01-38-001 > Mar > 10 > A/C Reduced Windshield Clearing/Defrost Control Module HVAC: All Technical Service Bulletins A/C - Reduced Windshield Clearing/Defrost TECHNICAL Bulletin No.: 10-01-38-001 Date: March 02, 2010 Subject: Reduced Windshield Clearing\Defrost at Low Ambient Temperatures (Reprogram HVAC Control Module) Models: 2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with HVAC System RPOs C42, C67 or CJ3 All Built Prior to February 17, 2010 Condition In rare cases, some customers may comment that the HVAC system has reduced defrost or added difficulty keeping the windshield clear in low ambient temperatures. Cause This condition may be caused by the airflow calibrations which can contribute to the above condition. Calibration changes at the start of the 2010 model year may not meet some customers' expectations. Testing has confirmed that defrost levels will meet requirements. Correction Important DO NOT replace the HVAC Control Module for this concern. Reprogram the HVAC Control Module with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest calibrations available on TIS2WEB. Refer to HVAC System Control Module Programming and Setup in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13413 Control Module HVAC: Diagrams Component Connector End Views HVAC Control Module X1 (CJ2) HVAC Control Module X2 (C67, C42 or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13414 HVAC Control Module X2 (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13415 HVAC Control Module X3 (C67, C42, CJ2 or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13416 Blower Motor Control Module X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13417 Blower Motor Control Module X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13418 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic Control Module HVAC: Service and Repair HVAC - Automatic HVAC Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13421 Control Module HVAC: Service and Repair HVAC - Manual HVAC Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13422 Control Module HVAC: Service and Repair Blower Motor Control Module Replacement Blower Motor Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > Air Conditioning System Seal Replacement A/C Coupler O-ring: Service and Repair Air Conditioning System Seal Replacement Air Conditioning System Seal Replacement Removal Procedure 1. Remove the seal washer from the A/C refrigerant component. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. Important: DO NOT reuse sealing washer. 4. Discard the sealing washer. Installation Procedure Important: Flat washer type seals do not require lubrication. 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. Important: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. 5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > Air Conditioning System Seal Replacement > Page 13428 A/C Coupler O-ring: Service and Repair Air Conditioning O-Ring Seal Replacement Air Conditioning O-Ring Seal Replacement Removal Procedure 1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure * For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). * For banjo style fittings remove the bolt retaining the banjo type fitting. 2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 5. Cap or tape the A/C refrigerant components. 6. Discard the O-ring seal. Installation Procedure 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. Important: DO NOT reuse O-ring seals. 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. 6. The O-ring seal must be fully seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > Air Conditioning System Seal Replacement > Page 13429 7. Assemble the A/C components. Refer to the appropriate repair procedure. * For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. * For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement - Lower Left Side Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Left Side Duct Air Temperature Sensor Replacement - Lower Left Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement - Lower Left Side > Page 13434 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Right Side Duct Air Temperature Sensor Replacement - Lower Right Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement - Lower Left Side > Page 13435 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Upper Left Side Duct Air Temperature Sensor Replacement - Upper Left Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement - Lower Left Side > Page 13436 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Upper Right Side Duct Air Temperature Sensor Replacement - Upper Right Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 13445 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 13446 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 13452 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 13453 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 13454 Evaporator Core: Service and Repair Air Conditioning Evaporator Core Replacement (Without HP2) Removal Procedure 1. Remove the HVAC module. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (See: Housing Assembly HVAC/Service and Repair). 2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screw driver and a hammer. 3. Disconnect all wiring connections from blower motor, blower motor control module and sensors. Also, remove all wiring from retainers before removal. 4. If equipped remove the screws from the HVAC module assembly. 5. Remove the evaporator cowl gasket from the evaporator. 6. Separate the upper HVAC module assembly (2) from the lower HVAC module assembly (1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 13455 7. Remove the evaporator core (1) from the upper HVAC module assembly (2). 8. Remove the air conditioning evaporator air temperature sensor. Refer to Air Conditioning Refrigerant Temperature Sensor Replacement (See: Refrigerant Temperature Sensor/Service and Repair/HVAC - Automatic) Installation Procedure Note: If replacing the evaporator core, add the refrigerant oil to the evaporator core. Refer to Refrigerant System Specifications (Non-HP2) ( See: Refrigerant Oil/Specifications). 1. Install the evaporator core (1) to the HVAC module assembly (2). 2. Install the upper HVAC module assembly (2) from the lower HVAC module assembly (1) 3. Install the evaporator cowl gasket to the evaporator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the screws to the HVAC module assembly. Tighten the screws to 2 Nm (18 lb in). 5. Install the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (See: Housing Assembly HVAC/Service and Repair). 6. Install the air conditioning evaporator air temperature sensor. Refer to Air Conditioning Refrigerant Temperature Sensor Replacement (See: Refrigerant Temperature Sensor/Service and Repair/HVAC - Automatic) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams Evaporator Temperature Sensor / Switch: Diagrams Component Connector End Views Air Temperature Sensor - Inside (CJ2) Air Temperature Sensor - Lower Left (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 13459 Air Temperature Sensor - Lower Right (CJ2) Air Temperature Sensor - Upper Left (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 13460 Air Temperature Sensor - Upper Right (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 13461 Evaporator Temperature Sensor (except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair Expansion Block/Orifice Tube: Service and Repair Expansion (Orifice) Tube Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Cover Replacement Heater Core: Service and Repair Heater Core Cover Replacement Heater Core Cover Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Cover Replacement > Page 13469 Heater Core: Service and Repair Heater Core Replacement Heater Core Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) Heater Hose: Service and Repair Heater Inlet Hose Replacement (Non-HP2) Heater Inlet Hose Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. Quick Connect Fittings 5. Pull the connection apart. 6. Remove the inlet heater hose from the water pump. 7. Remove the inlet heater hose. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 13474 Installation Procedure 1. Install the inlet heater hose. 2. Install the inlet heater hose to the water pump. 3. Connect the heater hose to the heater core. Important: Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hoses to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 13475 Heater Hose: Service and Repair Heater Outlet Hose Replacement (Non-HP2) Heater Outlet Hose Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. Quick Connect Fittings 5. Pull the connection apart. 6. Remove the outlet heater hose from the water pump. 7. Reposition the outlet heater hose clamp at the surge tank. 8. Remove the outlet heater hose from the surge tank. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 13476 9. Remove the outlet heater hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Important: Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Pull the heater outlet hose to ensure the connection. 7. Install the heater and surge tank hoses to the mounting clip. 8. Install the air intake tube. 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement Hose/Line HVAC: Service and Repair Discharge Hose Replacement Discharge Hose Replacement (LY2, LMF, L76 and L92) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Service and Repair). 2. Remove the discharge hose mounting bolt (2) from the A/C compressor. 3. Remove the discharge hose (1) from the A/C compressor. 4. Remove the upper radiator baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 5. Remove the discharge hose nut from the condenser. 6. Remove the discharge hose from the condenser. 7. Disconnect the electrical connector from the A/C recirculation switch. 8. Remove the discharge hose from the vehicle. 9. Discard all of the used sealing washers. Cap the system openings. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 13481 1. Install the discharge hose (1) to the vehicle. 2. Install the discharge hose to the condenser using new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the discharge hose nut to the condenser and tighten to 16 Nm (12 lb ft). 4. Install the upper air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 5. Connect the electrical connector to the A/C recirculation switch. 6. Install the discharge hose (1) to the A/C compressor using new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 7. Install the discharge hose mounting bolt and tighten to 16 Nm (12 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Refrigerant/Service and Repair )Refrigerant Recovery and Recharging (HP2) (See: Service and Repair). 9. Leak test the fittings of the component using the J 39400-A . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 13482 Hose/Line HVAC: Service and Repair Suction Hose Replacement Suction Hose Replacement (LY2, LMF, L76 and L92) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 13483 Hose/Line HVAC: Service and Repair Air Conditioning Evaporator Tube Replacement (Non-HP2) Air Conditioning Evaporator Tube Replacement (Non-HP2) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Service and Repair). 2. Remove the upper radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 4. Remove the surge tank hold down nut and bolt and position aside. Note: Do not open cooling system. 5. Remove the evaporator tube nut from the evaporator. 6. Disconnect the evaporator tube from the evaporator. 7. Remove the evaporator tube nut from the auxiliary A/C tube, if equipped. 8. Disconnect the evaporator tube from the auxiliary A/C tube, if equipped. 9. Remove the evaporator tube nut from the condenser. 10. Disconnect the evaporator tube from the condenser. 11. Remove the evaporator tube from the vehicle. 12. Discard all of the used sealing washers. Cap all of the open connections. Installation Procedure 1. Connect the evaporator tube to the condenser using new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 13484 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the evaporator tube nut to the condenser and tighten to 16 Nm (12 lb ft). 3. Connect the evaporator tube to the auxiliary A/C tube using new sealing washers, if equipped. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 4. Install the evaporator tube nut to the auxiliary A/C tube, if equipped, and tighten to 16 Nm (12 lb ft). 5. Install the evaporator tube to the evaporator. 6. Install the evaporator tube nut to the evaporator and tighten to 16 Nm (12 lb ft). 7. Install the surge tank hold down nut and bolt and position aside. 8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 9. Install the upper radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Service and Repair). 11. Leak test the fittings of the components using the J 39400-A . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair Housing Assembly HVAC: Service and Repair Air Conditioning and Heater Module Assembly Removal and Installation Special Tools J 43181 Heater Line QC Release Tool Removal Procedure 1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Using the J 43181 disconnect the inlet heater hose from the heater core. 1. Install the J 43181 to the heater core pipe. 2. Close the tool around the heater core pipe. 3. Firmly pull the tool into the quick connect end of the heater hose. 4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the inlet hose from the heater core. 3. Using the J 43181 disconnect the surge tank outlet hose from the heater core. 1. Install the J 43181 to the heater core pipe. 2. Close the tool around the heater core pipe. 3. Firmly pull the tool into the quick connect end of the heater hose. 4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the surge tank outlet hose from the heater core. 4. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 5. Remove the battery. Refer to Battery Replacement (See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery Replacement). 6. Remove the accumulator. Refer to Air Conditioning Accumulator Replacement (Non-HP2) (). 7. Remove the instrument panel to the service position. Refer to Instrument Panel Service Positioning (with SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (with SLT))Instrument Panel Service Positioning (without SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (without SLT)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 13488 8. Remove the nuts (2) from the HVAC module (3). 9. Remove the bolts (1) from the HVAC module (3). 10. Remove the HVAC module (3). Installation Procedure 1. If replacing the HVAC module, transfer the components from the old HVAC module as necessary. 2. Install the HVAC module (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the nuts (2) to the HVAC module (3). Tighten the nuts to 9 Nm (80 lb in). 4. Install the bolts (1) to the HVAC module (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 13489 Tighten the bolts to 4 Nm (35 lb in). 5. Connect the electrical harness and the ground connections. 6. Install the HVAC module drain hose. 7. Install the instrument panel. Refer to Instrument Panel Service Positioning (with SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (with SLT))Instrument Panel Service Positioning (without SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (without SLT)). 8. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 9. Install the battery. Refer to Battery Replacement (See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery Replacement). 10. Install the accumulator. Refer to Air Conditioning Accumulator Replacement (Non-HP2) (). 11. Install the surge tank outlet hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 12. Install the inlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 13. Fill the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 13494 Refrigerant: Fluid Type Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 13495 Refrigerant: Service and Repair Refrigerant Recovery and Recharging (Non-HP2) Special Tools * J 43600 - ACR 2000 Air Conditioning Service Center * J 45037 - A/C Oil Injector For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Heating, Ventilation, and Air Conditioning). Warning To prevent personal injury, avoid breathing A/C Refrigerant and lubricant vapor or mist. Work in a well ventilated area. To remove refrigerant from the A/C System, use service equipment designed for recovery that is certified to meet the requirements of the appropriate SAE Standards. If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant, refrigerant recovery, and lubricant manufacturers. Warning For personal protection, goggles and lint-free gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Caution: You must replace the desiccant if the A/C refrigerant system has been open to atmosphere for more than four hours, or if the A/C refrigerant oil has been contaminated. Failure to replace the desiccant will result in damage to the A/C refrigerant system. Caution: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. Caution: To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Caution: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. Caution: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 - service center is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 - service center ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Specifications (Non-HP2) (See: Refrigerant Oil/Specifications) for the correct amount. A/C Refrigerant System Oil Charge Replenishing If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 - injector. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Specifications (Non-HP2) (See: Refrigerant Oil/Specifications). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 13500 Refrigerant Oil: Fluid Type Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Refrigerant Pressure Sensor (Gas except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning Cycling Switch Replacement (Non-HP2) Air Conditioning Cycling Switch Replacement (Non-HP2) Removal Procedure 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. Installation Procedure 1. Install the new O-ring seal to the switch. Refer to Air Conditioning O-Ring Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning O-Ring Seal Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the A/C low pressure switch to the accumulator and tighten to 6 Nm (53 lb in). 3. Connect the electrical connector to the A/C low pressure switch. 4. Leak test the fittings of the components using the J 39400-A . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) > Page 13506 Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (Non-HP2) Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (Non-HP2) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Disconnect the electrical connector from the A/C refrigerant pressure sensor. 2. Remove the A/C refrigerant pressure sensor (1) from the condenser tube. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) > Page 13507 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the A/C refrigerant pressure sensor (1). Tighten the switch to 6 Nm (53 lb in). 2. Connect the electrical connector to the A/C refrigerant pressure sensor. 3. Leak test the fittings of the components using the J 39400-A . 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic Refrigerant Temperature Sensor: Service and Repair HVAC - Automatic Air Conditioning Refrigerant Temperature Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic > Page 13512 Refrigerant Temperature Sensor: Service and Repair HVAC - Manual Air Conditioning Refrigerant Temperature Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 13517 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 13518 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 13519 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 13520 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 13521 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 13522 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 13523 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11-01-38-001 > Feb > 11 > A/C - Excessive Cabin Moisture/Reduced Window Clearing Control Module HVAC: All Technical Service Bulletins A/C - Excessive Cabin Moisture/Reduced Window Clearing TECHNICAL Bulletin No.: 11-01-38-001 Date: February 28, 2011 Subject: Excessive Cabin Moisture / Reduced Window Clearing (Reprogram HVAC System Control Module) Models: 2010-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL All with RPO CJ3 or C67 (Manual Air Conditioning) Condition In rare cases, some customers may comment on excessive cabin moisture or difficulty keeping the windows clear in low ambient temperatures. Cause This concern may be caused by the recirculation door being in the recirculation position while the mode is set to a floor through defrost position. Correction Important DO NOT replace the HVAC control module for this concern. Revised software has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest software currently available in TIS2WEB. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 10-01-38-001 > Mar > 10 > A/C - Reduced Windshield Clearing/Defrost Control Module HVAC: All Technical Service Bulletins A/C - Reduced Windshield Clearing/Defrost TECHNICAL Bulletin No.: 10-01-38-001 Date: March 02, 2010 Subject: Reduced Windshield Clearing\Defrost at Low Ambient Temperatures (Reprogram HVAC Control Module) Models: 2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with HVAC System RPOs C42, C67 or CJ3 All Built Prior to February 17, 2010 Condition In rare cases, some customers may comment that the HVAC system has reduced defrost or added difficulty keeping the windshield clear in low ambient temperatures. Cause This condition may be caused by the airflow calibrations which can contribute to the above condition. Calibration changes at the start of the 2010 model year may not meet some customers' expectations. Testing has confirmed that defrost levels will meet requirements. Correction Important DO NOT replace the HVAC Control Module for this concern. Reprogram the HVAC Control Module with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest calibrations available on TIS2WEB. Refer to HVAC System Control Module Programming and Setup in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 11-01-38-001 > Feb > 11 > A/C - Excessive Cabin Moisture/Reduced Window Clearing Control Module HVAC: Customer Interest A/C - Excessive Cabin Moisture/Reduced Window Clearing TECHNICAL Bulletin No.: 11-01-38-001 Date: February 28, 2011 Subject: Excessive Cabin Moisture / Reduced Window Clearing (Reprogram HVAC System Control Module) Models: 2010-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL All with RPO CJ3 or C67 (Manual Air Conditioning) Condition In rare cases, some customers may comment on excessive cabin moisture or difficulty keeping the windows clear in low ambient temperatures. Cause This concern may be caused by the recirculation door being in the recirculation position while the mode is set to a floor through defrost position. Correction Important DO NOT replace the HVAC control module for this concern. Revised software has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest software currently available in TIS2WEB. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 10-01-38-001 > Mar > 10 > A/C - Reduced Windshield Clearing/Defrost Control Module HVAC: Customer Interest A/C - Reduced Windshield Clearing/Defrost TECHNICAL Bulletin No.: 10-01-38-001 Date: March 02, 2010 Subject: Reduced Windshield Clearing\Defrost at Low Ambient Temperatures (Reprogram HVAC Control Module) Models: 2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with HVAC System RPOs C42, C67 or CJ3 All Built Prior to February 17, 2010 Condition In rare cases, some customers may comment that the HVAC system has reduced defrost or added difficulty keeping the windshield clear in low ambient temperatures. Cause This condition may be caused by the airflow calibrations which can contribute to the above condition. Calibration changes at the start of the 2010 model year may not meet some customers' expectations. Testing has confirmed that defrost levels will meet requirements. Correction Important DO NOT replace the HVAC Control Module for this concern. Reprogram the HVAC Control Module with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest calibrations available on TIS2WEB. Refer to HVAC System Control Module Programming and Setup in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13545 Control Module HVAC: Diagrams Component Connector End Views HVAC Control Module X1 (CJ2) HVAC Control Module X2 (C67, C42 or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13546 HVAC Control Module X2 (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13547 HVAC Control Module X3 (C67, C42, CJ2 or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13548 Blower Motor Control Module X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13549 Blower Motor Control Module X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13550 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic Control Module HVAC: Service and Repair HVAC - Automatic HVAC Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13553 Control Module HVAC: Service and Repair HVAC - Manual HVAC Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13554 Control Module HVAC: Service and Repair Blower Motor Control Module Replacement Blower Motor Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views Ambient Air Temperature Sensor (CJ2 or C67) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 13559 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement Removal Procedure 1. Remove the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 2. Remove the left center pillar assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair/Roof Rail Rear Assist Handle Replacement). 3. Remove the center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Garnish Molding Replacement). 4. Remove the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair). 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. Installation Procedure 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Page 13563 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair). 5. Install the left center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Garnish Molding Replacement). 6. Install the left center assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair/Roof Rail Rear Assist Handle Replacement). 7. Install the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Left Side Duct Air Temperature Sensor Replacement - Lower Left Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side > Page 13568 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Right Side Duct Air Temperature Sensor Replacement - Lower Right Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side > Page 13569 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Upper Left Side Duct Air Temperature Sensor Replacement - Upper Left Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side > Page 13570 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Upper Right Side Duct Air Temperature Sensor Replacement - Upper Right Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams Evaporator Temperature Sensor / Switch: Diagrams Component Connector End Views Air Temperature Sensor - Inside (CJ2) Air Temperature Sensor - Lower Left (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 13574 Air Temperature Sensor - Lower Right (CJ2) Air Temperature Sensor - Upper Left (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 13575 Air Temperature Sensor - Upper Right (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 13576 Evaporator Temperature Sensor (except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Refrigerant Pressure Sensor (Gas except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning Cycling Switch Replacement (Non-HP2) Air Conditioning Cycling Switch Replacement (Non-HP2) Removal Procedure 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. Installation Procedure 1. Install the new O-ring seal to the switch. Refer to Air Conditioning O-Ring Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning O-Ring Seal Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the A/C low pressure switch to the accumulator and tighten to 6 Nm (53 lb in). 3. Connect the electrical connector to the A/C low pressure switch. 4. Leak test the fittings of the components using the J 39400-A . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) > Page 13582 Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (Non-HP2) Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (Non-HP2) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Disconnect the electrical connector from the A/C refrigerant pressure sensor. 2. Remove the A/C refrigerant pressure sensor (1) from the condenser tube. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) > Page 13583 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the A/C refrigerant pressure sensor (1). Tighten the switch to 6 Nm (53 lb in). 2. Connect the electrical connector to the A/C refrigerant pressure sensor. 3. Leak test the fittings of the components using the J 39400-A . 4. Lower the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic Refrigerant Temperature Sensor: Service and Repair HVAC - Automatic Air Conditioning Refrigerant Temperature Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic > Page 13588 Refrigerant Temperature Sensor: Service and Repair HVAC - Manual Air Conditioning Refrigerant Temperature Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams Solar Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C67, C42 or MEX) Ambient Light/Sunload Sensor (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 13592 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 13593 Solar Sensor: Service and Repair Sun Load Temperature Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams Solar Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C67, C42 or MEX) Ambient Light/Sunload Sensor (CJ2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Page 13597 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Page 13598 Solar Sensor: Service and Repair Sun Load Temperature Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Seat Belts Repairs and Inspections Required After a Collision: Service and Repair Seat Belts Repairs and Inspections Required After a Collision Warning Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: * Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. * Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. * Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. * Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Seat Belts > Page 13604 Repairs and Inspections Required After a Collision: Service and Repair Supplemental Inflatable Restraints Repairs and Inspections Required After a Collision Accident With or Without Inflator Module Deployment - Component Inspections Caution: Proper operation of the SIR sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment in a collision or deployment for conditions less severe than intended. After any collision, inspect the following components as indicated. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. * Hybrid vehicles-Perform an inspection of the high voltage system for damage. Refer to High Voltage System Inspection (). * The steering column-Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection (See: Steering and Suspension/Steering/Steering Column/Testing and Inspection/Initial Inspection and Diagnostic Overview). * The instrument panel (I/P) knee bolsters and mounting points-Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. * The I/P brackets, braces, etc.-Inspect for bending, twisting, buckling, or any other type of damage. * The seat belts-Perform the seat belt operational and functional checks. Refer to Seat Belt System Operational and Functional Checks (See: Seat Belt Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview). * The I/P mounting points and brackets-Inspect for bending, twisting, buckling, or any other type of damage. * The roof rail and roof rail module mounting points-Inspect for bending, twisting, buckling, or any other type of damage. * The seats and seat mounting points-Inspect for bending, twisting, buckling, or any other type of damage. * Passenger seat bottom equipped with Passenger Presence System (PPS)-Check for any DTCs or problems that may cause the PPS not to function properly. Accident With Frontal Air Bag Deployment - Component Replacement and Inspections After a collision involving air bag deployment, replace the following components. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. Important: The front passenger seat is equipped with a PPS, which detects an occupant. If the requirements for disabling the I/P air bag are met then the PPS will communicate with the SDM to disable/turn off the I/P air bag, even in a accident. For more information on the PPS refer to SIR System Description and Operation (See: Air Bag Systems/Description and Operation). * Inflatable restraint front end sensors * Inflatable restraint I/P module, if deployed and after performing the necessary inspections listed above * Inflatable restraint sensing and diagnostic module (SDM) * Inflatable restraint steering wheel module * Inflatable restraint steering wheel module coil * Seat belt pretensioners Perform additional inspections on the following components: * Steering wheel module coil and the coil wiring pigtail-Inspect for melting, scorching, or other damage due to excessive heat. * Mounting points or mounting hardware for the I/P module, steering wheel module, SDM, front end sensors, seat belt pretensioners, and vehicle rollover sensor-Inspect for any damage and repair or replace each component as needed. Accident With Side Air Bag Deployment - Component Replacement and Inspections After a collision involving side air bag deployment, replace the following components: * Inflatable restraint roof rail module, on the side of the impact. * Inflatable restraint side impact sensors (SIS) (front/rear), on the side of the impact * Inflatable restraint SDM * Seat belt pretensioner, on the side of impact. Perform additional inspections on the following components: * Mounting points or mounting hardware for the SIS, roof rail module (left/right), and seat belt pretensioner on the side of impact-Inspect for any damage and repair or replace each component as needed. * Mounting points or mounting hardware for the SDM and vehicle rollover sensor-Inspect for any damage and repair or replace each component as needed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Seat Belts > Page 13605 Sensor Replacement Guidelines The SIR/side air bag sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. An example of this would be a moderate collision where the front of the vehicle impacts a tree, if the vehicle has an SIR sensor mounted forward of the radiator, replace the SIR sensor. * Replace the sensor whether or not the air bags have deployed. * Replace the sensor even if the sensor appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR/side air bag sensing system. Do not try to determine whether the sensor is undamaged. Replace the sensor. Also, if you follow a diagnostic trouble code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 13610 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13620 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13621 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13627 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13628 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13637 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13638 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13644 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13645 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13646 Air Bag Control Module: Locations Harness Routing Views Body Harness Routing (Regular Cab) 1 - X200 2 - G302 3 - X319 (AZ3/D07 with UQ3) 4 - JX339 (except MEX) 5 - X305 (except MEX) 6 - G304 (except MEX) 7 - J304 (AG2) 8 - J303 9 - X303 (except MEX) 10 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 11 - X275 12 - X202 13 - X500 (YE9 without AN3/DL3) 14 - X501 (YE9 without AN3/DL3) 15 - X601 (ASF) 16 - X600 (YE9 without AN3/DL3) Body Harness Routing (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13647 1 - X700 2 - G303 3 - X303 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 5 - X501 (YE9 without AN3/DL3) 6 - X275 7 - X208 (A48) 8 - X202 9 - X500 (YE9 without AN3/DL3) 10 - G301 11 - J304 12 - X200 13 - X601 (ASF) 14 - X600 (YE9 without AN3/DL3) 15 - G302 16 - JX339 17 - X305 18 - X319 (AZ3/D07 with UQ3) 19 - X800 20 - J302 21 G304 22 - X320 (A48) 23 - J303 24 - X322 (UD7) 25 - Floor Panel Body Harness Routing (Crew Cab except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13648 1 - X601 (ASF) 2 - X309 (Y91) 3 - G302 4 - J302 5 - JX339 6 - G301 7 - J304 8 - X305 9 - X800 10 - G304 11 - G307 12 - X320 (A48) 13 - J303 14 - G303 15 - X700 16 - X303 17 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 18 - X501 (YE9 without AN3/DL3) 19 X502 (ASF without YE9 or with AN3) 20 - X202 21 - X500 (YE9 without AN3/DL3) 22 - X208 (A48) 23 - X600 (YE9 without AN3/DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13649 Air Bag Control Module: Diagrams Component Connector End Views Inflatable Restraint Sensing and Diagnostic Module (SDM) X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13650 Inflatable Restraint Sensing and Diagnostic Module (SDM) X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13651 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13652 Inflatable Restraint Side Impact Module - Left (10 Series except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13653 Inflatable Restraint Side Impact Module - Left (HP2) Inflatable Restraint Side Impact Module - Right (10 Series except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13654 Inflatable Restraint Side Impact Module - Right (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13655 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Locations Air Bag Deactivation Indicator: Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Locations > Page 13659 Air Bag Deactivation Indicator: Diagrams Component Connector End Views Inflatable Restraint I/P Module Indicator (AL0 or C99 except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Locations > Page 13660 Air Bag Deactivation Indicator: Service and Repair Inflatable Restraint Instrument Panel Module Indicator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Diagrams Air Bag Deactivation Switch: Diagrams Component Connector End Views Inflatable Restraint I/P Module Disable Switch (C99 or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Diagrams > Page 13664 Air Bag Deactivation Switch: Service and Repair Instrument Panel Inflatable Restraint Module Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams Component Connector End Views Inflatable Restraint Steering Wheel Module Coil X1 Inflatable Restraint Steering Wheel Module Coil X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 13668 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures Clockspring Assembly / Spiral Cable: Procedures Inflatable Restraint Steering Wheel Module Coil Centering Caution: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. 1. Verify the following conditions before centering the SIR coil: * The front wheels of the vehicle are in the straight ahead position. * The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. * The ignition switch is in the LOCK position. Note: If a double wire harness strap is installed onto the wire harness assembly and the column, you must reuse the holder for the wire straps during the installation. 2. Remove the wire harness strap or straps where necessary. 3. Hold the SIR coil and look at the side with the letters POM (1). 4. Rotate the coil hub clockwise until the coil ribbon stops. Caution: Do not rotate the SIR coil more than 3 turns counterclockwise from the center position. There is no stop in the counterclockwise direction. Rotating the SIR coil more than 3 turns counterclockwise from the center position will damage the SIR coil, causing an inflatable restraint malfunction. 5. From the clockwise stop, rotate the coil hub slowly counterclockwise approximately 3.3 turns. Place the uplead connector (2) in the 12 o'clock position. Ensure the flat wire cable loop appears in the centering window (4). This is the CENTER position. 6. If you have the orange lock pin (3), use the lock pin to lock the SIR coil in the center position. If you do not have the orange lock pin, hold the SIR coil in the center position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 13671 7. Align the SIR coil with the horn tower and slide the SIR coil onto the steering shaft assembly. 8. If a double wire harness strap is installed onto the wire harness assembly and the column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all other leads to the steering column. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 13672 Clockspring Assembly / Spiral Cable: Removal and Replacement Steering Wheel Inflatable Restraint Module Coil Replacement Special Tools J 42640 Steering Column Anti-rotation Pin Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. Verify the following before removing the inflatable restraint steering wheel module coil: * The wheels on the vehicle are straight ahead. * That anti-rotation pin J 42640 is installed or the ignition and start switch is in the LOCK position. 2. Remove the steering wheel. Refer to Steering Wheel Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Replacement). 3. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 4. Disconnect any electrical connectors as needed. 5. Remove the inflatable restraint steering wheel module coil retaining ring (2) and discard it. DO NOT reuse the ring. 6. Remove the inflatable restraint steering wheel module coil (1) from the steering shaft. 7. If replacing, discard the old inflatable restraint steering wheel module coil. Installation Procedure Caution: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 13673 Note: Do not remove the centering tab from the new inflatable restraint steering wheel module coil until the installation is complete. If the centering tab is missing then re-center the assembly. 1. If reusing the existing inflatable restraint steering wheel module coil it MUST be centered. Refer to Inflatable Restraint Steering Wheel Module Coil Centering (See: Procedures). 2. Align the inflatable restraint steering wheel module coil (1) with the horn tower on the turn signal switch cancel cam (2). 3. Slide the inflatable restraint steering wheel module coil (4) onto the steering shaft (2). 4. Firmly seat the new inflatable restraint steering wheel module coil retaining ring (3) into the appropriate groove on the steering shaft (2). 5. Remove and discard the centering tab from the new inflatable restraint steering wheel module coil (4). 6. Connect any electrical connectors as needed. 7. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 8. Install the steering wheel. Refer to Steering Wheel Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Replacement). 9. Remove anti-rotation pin J 42640 . Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams Impact Sensor: Diagrams Component Connector End Views Inflatable Restraint Front End Sensor - Left (10 Series) Inflatable Restraint Front End Sensor - Right (10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Page 13677 Inflatable Restraint Front End Sensor (except 10 Series) Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Page 13678 Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended or Crew Cab with ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Page 13679 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended or Crew Cab with ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement Inflatable Restraint Front End Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13682 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13683 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13684 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab, Rear Door) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab, Rear Door) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13685 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13686 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Extended Cab, Rear Door ) Inflatable Restraint Side Impact Sensor Replacement (Extended Cab, Rear Door ) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13687 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Diagrams Seat Occupant Classification Module - Air Bag: Diagrams Component Connector End Views Inflatable Restraint Passenger Presence System (PPS) Module (AL0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 13695 Seat Occupant Sensor: Service and Repair Inflatable Restraint Passenger Presence System Replacement - Front (without HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 13696 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations Seat Position Sensor: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 13700 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 13701 Seat Position Sensor: Diagrams Component Connector End Views Inflatable Restraint Seat Position Sensor - Driver (10 Series except MEX) Inflatable Restraint Seat Position Sensor - Passenger (10 Series except Crew Cab or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 13702 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 13703 Seat Position Sensor: Service and Repair Inflatable Restraint Seat Position Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Replacement (With SLT) Knee Diverter: Service and Repair Knee Bolster Replacement (With SLT) Knee Bolster Replacement (With SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Replacement (With SLT) > Page 13712 Knee Diverter: Service and Repair Knee Bolster Replacement (Without SLT) Knee Bolster Replacement (Without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13722 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13723 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13729 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13730 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13731 Air Bag Control Module: Locations Harness Routing Views Body Harness Routing (Regular Cab) 1 - X200 2 - G302 3 - X319 (AZ3/D07 with UQ3) 4 - JX339 (except MEX) 5 - X305 (except MEX) 6 - G304 (except MEX) 7 - J304 (AG2) 8 - J303 9 - X303 (except MEX) 10 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 11 - X275 12 - X202 13 - X500 (YE9 without AN3/DL3) 14 - X501 (YE9 without AN3/DL3) 15 - X601 (ASF) 16 - X600 (YE9 without AN3/DL3) Body Harness Routing (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13732 1 - X700 2 - G303 3 - X303 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 5 - X501 (YE9 without AN3/DL3) 6 - X275 7 - X208 (A48) 8 - X202 9 - X500 (YE9 without AN3/DL3) 10 - G301 11 - J304 12 - X200 13 - X601 (ASF) 14 - X600 (YE9 without AN3/DL3) 15 - G302 16 - JX339 17 - X305 18 - X319 (AZ3/D07 with UQ3) 19 - X800 20 - J302 21 G304 22 - X320 (A48) 23 - J303 24 - X322 (UD7) 25 - Floor Panel Body Harness Routing (Crew Cab except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13733 1 - X601 (ASF) 2 - X309 (Y91) 3 - G302 4 - J302 5 - JX339 6 - G301 7 - J304 8 - X305 9 - X800 10 - G304 11 - G307 12 - X320 (A48) 13 - J303 14 - G303 15 - X700 16 - X303 17 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 18 - X501 (YE9 without AN3/DL3) 19 X502 (ASF without YE9 or with AN3) 20 - X202 21 - X500 (YE9 without AN3/DL3) 22 - X208 (A48) 23 - X600 (YE9 without AN3/DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13734 Air Bag Control Module: Diagrams Component Connector End Views Inflatable Restraint Sensing and Diagnostic Module (SDM) X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13735 Inflatable Restraint Sensing and Diagnostic Module (SDM) X2 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13736 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13737 Inflatable Restraint Side Impact Module - Left (10 Series except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13738 Inflatable Restraint Side Impact Module - Left (HP2) Inflatable Restraint Side Impact Module - Right (10 Series except HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13739 Inflatable Restraint Side Impact Module - Right (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13740 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Diagrams Seat Occupant Classification Module - Air Bag: Diagrams Component Connector End Views Inflatable Restraint Passenger Presence System (PPS) Module (AL0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 13748 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair Child Seat Tether Attachment: Service and Repair Child Seat Restraint System Belt Bracket Replacement (Ext Cab/Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions Seat Belt: Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 13757 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt Latch Stop Installation Seat Belt: Service and Repair Seat Belt Latch Stop Installation Seat Belt Latch Stop Installation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt Latch Stop Installation > Page 13760 Seat Belt: Service and Repair Seat Belt Replacement - Center Rear (Extended Cab) Seat Belt Replacement - Center Rear (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt Latch Stop Installation > Page 13761 Seat Belt: Service and Repair Seat Belt Replacement - Center Rear (Crew Cab) Seat Belt Replacement - Center Rear (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 13770 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 07-09-41-010D > May > 10 > Restraints - Airbag Light On DTC B0071 And B0081 Set Seat Belt Buckle: Customer Interest Restraints - Airbag Light On DTC B0071 And B0081 Set TECHNICAL Bulletin No.: 07-09-41-010D Date: May 03, 2010 Subject: Airbag Light On, DTC B0071 and B0081 Set (Diagnose and Replace Right Front Seatbelt Buckle, If Necessary) Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Colorado, Silverado LD, Suburban, Tahoe 2007-2010 GMC Canyon, Sierra LD, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2006-2010 HUMMER H3 2009-2010 HUMMER H3T Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 07-09-41-010C (Section 09 - Restraints). Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0071 set in the passenger presence system (PPS) and a DTC B0081 in the sensing and diagnostics module (SDM). Correction Verify proper system electrical connections. Inspect the passenger seat belt tension sensor signal, voltage reference and low reference circuits, carefully for cutting and/or chaffing per SI instructions for DTC B0071. If all checks have been made and no fault has been found, replace the belt tension sensor. Important The seat belt tension sensor is not serviced separately. The seat belt buckle with the tension sensor must be serviced as a complete unit. Parts Information For part number and usage of seatbelt buckles, refer to Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 13780 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 07-09-41-010D > May > 10 > Restraints - Airbag Light On DTC B0071 And B0081 Set Seat Belt Buckle: All Technical Service Bulletins Restraints - Airbag Light On DTC B0071 And B0081 Set TECHNICAL Bulletin No.: 07-09-41-010D Date: May 03, 2010 Subject: Airbag Light On, DTC B0071 and B0081 Set (Diagnose and Replace Right Front Seatbelt Buckle, If Necessary) Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Colorado, Silverado LD, Suburban, Tahoe 2007-2010 GMC Canyon, Sierra LD, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2006-2010 HUMMER H3 2009-2010 HUMMER H3T Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 07-09-41-010C (Section 09 - Restraints). Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0071 set in the passenger presence system (PPS) and a DTC B0081 in the sensing and diagnostics module (SDM). Correction Verify proper system electrical connections. Inspect the passenger seat belt tension sensor signal, voltage reference and low reference circuits, carefully for cutting and/or chaffing per SI instructions for DTC B0071. If all checks have been made and no fault has been found, replace the belt tension sensor. Important The seat belt tension sensor is not serviced separately. The seat belt buckle with the tension sensor must be serviced as a complete unit. Parts Information For part number and usage of seatbelt buckles, refer to Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 07-09-40-002A > Jun > 09 > Restraints Seat Belt Latch Stop Button Availability Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 07-09-40-002A > Jun > 09 > Restraints Seat Belt Latch Stop Button Availability Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Driver or Passenger Seat Belt Buckle Replacement Seat Belt Buckle: Service and Repair Driver or Passenger Seat Belt Buckle Replacement Driver or Passenger Seat Belt Buckle Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Driver or Passenger Seat Belt Buckle Replacement > Page 13796 Seat Belt Buckle: Service and Repair Rear Seat Center Buckle Side Belt Replacement (Crew Cab) Rear Seat Center Buckle Side Belt Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Driver or Passenger Seat Belt Buckle Replacement > Page 13797 Seat Belt Buckle: Service and Repair Rear Seat Center Buckle Side Belt Replacement (Ext Cab w/AM7) Rear Seat Center Buckle Side Belt Replacement (Ext Cab w/AM7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Driver or Passenger Seat Belt Buckle Replacement > Page 13798 Seat Belt Buckle: Service and Repair Rear Seat Center Buckle Side Belt Replacement (Ext Cab w/A68) Rear Seat Center Buckle Side Belt Replacement (Ext Cab w/A68) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 13802 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 13803 Seat Belt Buckle Switch: Diagrams Component Connector End Views Seat Belt Buckle - Driver Seat Belt Buckle - Passenger X1 (10 Series without MEX) Seat Belt Buckle - Passenger X2 (AL0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 13804 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Seat Belt Height Adjuster Knob Replacement - Front Seat Belt Height Adjuster: Service and Repair Seat Belt Height Adjuster Knob Replacement - Front Seat Belt Height Adjuster Knob Replacement - Front Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Seat Belt Height Adjuster Knob Replacement - Front > Page 13813 Seat Belt Height Adjuster: Service and Repair Seat Belt Height Adjuster Replacement - Front Seat Belt Height Adjuster Replacement - Front Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions Seat Belt Retractor: Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 13818 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 13819 Seat Belt Retractor: Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Rear Seat Shoulder Belt Retractor Replacement (Crew Cab) Seat Belt Retractor: Service and Repair Rear Seat Shoulder Belt Retractor Replacement (Crew Cab) Rear Seat Shoulder Belt Retractor Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Rear Seat Shoulder Belt Retractor Replacement (Crew Cab) > Page 13822 Seat Belt Retractor: Service and Repair Rear Seat Shoulder Belt Retractor Replacement (Extended Cab) Rear Seat Shoulder Belt Retractor Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams Seat Belt Tensioner: Diagrams Component Connector End Views Seat Belt Pretensioner - Driver Seat Belt Pretensioner - Passenger Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 13826 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures Seat Belt Tensioner: Procedures Pretensioner Handling and Scrapping Warning When carrying an undeployed inflatable restraint seat belt pretensioner: * Do not carry the seat belt pretensioner by the wires or connector. * Carry the seat belt pretensioner by the piston tube, keeping hands and fingers away from the cable. * Make sure the open end of the seat belt pretensioner piston tube points away from you and other people. * Do not cover the seat belt pretensioner piston tube opening with your hand. Failure to observe these guidelines may result in personal injury. Scrapping Procedure During the course of a vehicles useful life, certain situations may arise which will require the disposal of a live and undeployed seat belt pretensioner. Do not dispose of a live and undeployed seat belt pretensioner through normal disposal channels until the seat belt pretensioner has been deployed. The following information covers the proper procedures for disposing of a live and undeployed seat belt pretensioner. Do not deploy the seat belt pretensioner in the following situations: * After replacement of a seat belt pretensioner under warranty. The seat belt pretensioner may need to be returned undeployed to the manufacturer. * If the vehicle is the subject of a Product Liability report, GM1241, related to the SIR system or the seat belt system. If the vehicle is subject to the Product Liability report, do not alter the SIR or seat belt system in any manner. * If the vehicle is involved in a campaign affecting the seat belt pretensioners. Follow the instructions in the Campaign Service Bulletin for proper SIR handling procedures. Deployment Procedures The seat belt pretensioner can be deployed inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation. Deployment Outside Vehicle for Seat Belt Pretensioners Deploy the seat belt pretensioners outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: * Using the SIR diagnostics, it is determined that the seat belt pretensioner is malfunctioning. * The seat belt pretensioner pigtail, if equipped, is damaged. * The seat belt pretensioner connector is damaged. * The seat belt pretensioner connector terminals are damaged. Deployment and disposal of a malfunctioning seat belt pretensioner is subject to any required retention period. Warning In order to prevent accidental deployment and the risk of personal injury, do not dispose of an undeployed inflatable restraint seat belt pretensioner as normal shop waste. Undeployed seat belt pretensioners contain substances that could cause severe illness or personal injury if their sealed containers are damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed seat belt pretensioner. Failure to observe the following disposal methods may be a violation of federal, state, or local laws. Special Tools * J 39401-B SIR Deployment Fixture * J 38826 SIR Deployment Harness * An appropriate pigtail adaptor Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 13829 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove the seat belt pretensioner from the vehicle. Refer to Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab))Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab))Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) ). 5. When carrying a seat belt pretensioner to the deployment area, keep fingers clear of the seat belt webbing. 6. Clear a space on the ground about 1.85 m (6 ft) in diameter for deployment of the seat belt pretensioner. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient ventilation. 7. Make sure no loose or flammable objects are in the area. 8. Place the J 39401-B in the center of the cleared area. 9. Fill the fixture plastic reservoir with water or sand. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 13830 10. Mount the seat belt pretensioner (1) in the SIR deployment fixture (3) with the open end facing up using the following mounting method. * Adjust and secure the J 39401-B arms (4) to the deployment fixture. * To mount, use the proper size bolt (2) and nut (5) with washers in order to secure the seat belt pretensioner (1) to the deployment fixture brackets. * Securely tighten all fasteners prior to deployment. 11. Inspect the J 38826 and the appropriate pigtail adapter for damage. Replace as needed. 12. Short the 2 SIR deployment harness (1) leads together using 1 banana plug seated into the other. 13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 13831 14. Extend the SIR deployment harness and adapter to full length from the deployment fixture. 15. Connect the seat belt pretensioner connector (1) to the adapter (2) on the deployment harness (3). Note: When deploying a seat belt pretensioner, the rapid expansion of gas is very loud. Notify the people in the immediate area that a seat belt pretensioner will be deployed. 16. Clear the area of people. 17. Separate the 2 banana plugs on the SIR deployment harness. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 13832 18. Place a 12 volt minimum/2 amp minimum power source, such as a vehicle battery, near the shorted end of the harness. 19. Connect the SIR deployment harness wires to the power source. Seat belt pretensioner deployment will occur when contact is made. 20. Disconnect the SIR deployment harness from the power source after the seat belt pretensioner deploys. 21. Seat one banana plug into the other in order to short the deployment harness leads. 22. If the seat pretensioner did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. 23. Put on a pair of shop gloves. 24. Disconnect the pigtail adapter from the seat belt pretensioner as soon as possible. 25. Dispose of the deployed seat belt pretensioner through normal refuse channels. 26. Wash hands with a mild soap. Deployment Inside Vehicle - Vehicle Scrapping Procedure Deploy the seat belt pretensioners inside of the vehicle when destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: * The vehicle has completed its useful life. * Irreparable damage occurs to the vehicle in a non-deployment type accident. * Irreparable damage occurs to the vehicle during a theft. * The vehicle is being salvaged for parts to be used on a vehicle with a different VIN as opposed to rebuilding as the same VIN. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 13833 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the seat belt pretensioner connector. Refer to Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab))Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab))Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab)). 6. Cut the seat belt pretensioner harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 8. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand wire. These wires will be used for the seat belt pretensioner deployment harness. 9. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 10. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the seat belt pretensioner. 11. Twist together one connector wire lead to one deployment wire. 12. Inspect that the previous connections is secure. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 13834 13. Bend flat the twisted connection. 14. Secure and insulate the connection using electrical tape. 15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 16. Connect the deployment harness to the seat belt pretensioner connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 13835 17. Route the deployment harness out of the driver side of the vehicle. 18. Disconnect the seat belt pretensioner connector. Refer to Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab))Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab))Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab)). 19. Cut the seat belt pretensioner connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 20. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 21. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand wire. These wires will be used for the seat belt pretensioner deployment harness. 22. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 23. Twist together one end from each of the wires in order to short the wires. The deployment wires are to remain shorted, and not connected to a power source until you are ready to deploy the seat belt pretensioner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 13836 24. Twist together one connector wire lead to one deployment wire. 25. Inspect that the previous connection is secure. 26. Bend flat the twisted connection. 27. Secure and insulate the connection using electrical tape. 28. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 13837 29. Connect the deployment harness to the seat belt pretensioner connector. 30. Route the deployment harness out of the passenger's side of the vehicle. 31. Completely cover the windshield and the front door openings with a drop cloth. 32. Deploy each deployment loop one at a time. 33. Stretch out all of the deployment harness wires on the left and right side of the vehicle to their full length. 34. Place a power source, 12 volt minimum/2 amp minimum, such as a vehicle battery, near the shorted end of the harnesses. 35. Separate one set of wires and touch the wire ends to the power source in order to deploy the seat belt pretensioners. 36. Disconnect the deployment harness from the power source and twist the wire ends together. 37. Continue the same process with the remaining deployment harnesses that are available. 38. Remove the drop cloth from the vehicle. 39. Disconnect all harnesses from the vehicle. 40. Discard the harnesses. 41. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 42. If one or more of the seat belt pretensioners did not deploy, perform the following steps to remove the undeployed seat belt pretensioner from the vehicle, refer to Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab))Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) (See: Removal and Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 13838 Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab))Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab)). 43. Call the Technical Assistance Group for further assistance. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 13839 Seat Belt Tensioner: Removal and Replacement Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 13840 Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 13841 Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 13842 Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Diagrams Air Bag Deactivation Switch: Diagrams Component Connector End Views Inflatable Restraint I/P Module Disable Switch (C99 or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Diagrams > Page 13847 Air Bag Deactivation Switch: Service and Repair Instrument Panel Inflatable Restraint Module Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams Impact Sensor: Diagrams Component Connector End Views Inflatable Restraint Front End Sensor - Left (10 Series) Inflatable Restraint Front End Sensor - Right (10 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 13851 Inflatable Restraint Front End Sensor (except 10 Series) Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 13852 Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended or Crew Cab with ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 13853 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended or Crew Cab with ASF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement Inflatable Restraint Front End Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13856 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13857 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13858 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab, Rear Door) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab, Rear Door) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13859 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13860 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Extended Cab, Rear Door ) Inflatable Restraint Side Impact Sensor Replacement (Extended Cab, Rear Door ) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13861 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 13865 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 13866 Seat Belt Buckle Switch: Diagrams Component Connector End Views Seat Belt Buckle - Driver Seat Belt Buckle - Passenger X1 (10 Series without MEX) Seat Belt Buckle - Passenger X2 (AL0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 13867 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 13872 Seat Occupant Sensor: Service and Repair Inflatable Restraint Passenger Presence System Replacement - Front (without HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 13873 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations Seat Position Sensor: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 13877 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 13878 Seat Position Sensor: Diagrams Component Connector End Views Inflatable Restraint Seat Position Sensor - Driver (10 Series except MEX) Inflatable Restraint Seat Position Sensor - Passenger (10 Series except Crew Cab or MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 13879 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 13880 Seat Position Sensor: Service and Repair Inflatable Restraint Seat Position Sensor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Audio System - Difficult To Install Fixed Radio Antenna Antenna Mast: Technical Service Bulletins Audio System - Difficult To Install Fixed Radio Antenna INFORMATION Bulletin No.: 07-08-44-001F Date: June 15, 2010 Subject: Information on Difficult to Install Fixed Radio Antenna Mast Models: 2006-2011 Cadillac Escalade EXT 2005-2010 Chevrolet Cobalt 2006-2009 Chevrolet TrailBlazer Models 2006-2011 Chevrolet Avalanche, Colorado, Silverado (Classic and New Style) 2006-2009 GMC Envoy 2006-2011 GMC Canyon, Sierra (Classic and New Style) 2006-2010 Pontiac G5 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years, a graphic with accompanying text and additional text in the Parts Information Description. Please discard Corporate Bulletin Number 07-08-44-001E (Section 08 - Body and Accessories). - A design change was made to the antenna base and antenna mast starting in October 2005. The radio antenna base size increased from 6 mm (0.23 in) to 7 mm (0.27 in) for improved stability and radio reception. - There are two different design antenna masts available. The antenna masts can be distinguished by the outer bottom of the antenna mast. The first design antenna mast (1) will have a six-sided hex design and a 6 mm (0.23 in) inside diameter thread. The second design antenna mast (2) will have two flats on the outer mast and a 7 mm (0.27 in) inside diameter thread. - The second design antenna mast will have more resistance when installing due to the interference fit of the threads in the mast as identified by the arrows in the graphic. Note Before proceeding, verify that the mast and base stud are properly aligned. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Audio System - Difficult To Install Fixed Radio Antenna > Page 13887 - A wrench will be needed to install the antenna mast. When starting to thread the antenna mast onto the base stud, interference will be felt. The interference is similar to the feeling of a cross threaded fastener. Important Use a protective tape or a cloth inside an adjustable wrench when installing the antenna mast. This will help prevent damage to the painted coating on the antenna mast. - Tighten the antenna mast. Tighten Tighten to 6 Nm (53 lb in). Parts Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Page 13888 Antenna Mast: Service and Repair Electronic Navigation Antenna Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Service and Repair Antenna, Phone: Service and Repair Mobile Telephone Digital Antenna Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Application and ID Antenna Cable: Application and ID Antenna Coaxial/Connector Cable Identification Table Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement (without RPO SLT) Antenna Cable: Service and Repair Radio Antenna Cable Extension Cable Replacement (without RPO SLT) Radio Antenna Cable Extension Cable Replacement (without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement (without RPO SLT) > Page 13898 Antenna Cable: Service and Repair Radio Antenna Cable Extension Cable Replacement (with RPO SLT) Radio Antenna Cable Extension Cable Replacement (with RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement (without RPO SLT) > Page 13899 Antenna Cable: Service and Repair Mobile Telephone and Navigation Antenna Coaxial Cable Replacement Mobile Telephone and Navigation Antenna Coaxial Cable Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams Alarm Module: Diagrams Component Connector End Views Theft Deterrent Module (TDM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 13904 Alarm Module: Service and Repair Theft Deterrent Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Antenna - Keyless Entry > Component Information > Service and Repair > Keyless Entry Antenna Replacement (Regular Cab) Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Regular Cab) Keyless Entry Antenna Replacement (Regular Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Antenna - Keyless Entry > Component Information > Service and Repair > Keyless Entry Antenna Replacement (Regular Cab) > Page 13913 Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Extended/Crew Cab) Keyless Entry Antenna Replacement (Extended/Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams Keyless Entry Receiver: Diagrams Component Connector End Views Remote Control Door Lock Receiver (RCDLR) (AP3 or AP8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter Diagnostic Tip INFORMATION Bulletin No.: 09-08-52-004A Date: January 08, 2010 Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter When Transmitter Battery is Weak or Dead Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR, Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories). Follow these procedures if a customer comments that their GM Accessory 2-way transmitter stopped communicating with the vehicle. About GM Accessory 2-Way Remote Start The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a 2-way advanced remote start system, but often the 2-way transmitter may only be coded to one vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter will enter second vehicle mode and will not control the original vehicle until a subsequent double press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of the 2-way transmitter should be thought of as an individual transmitter with its own unique code. Test the Transmitter Battery Note This test should be performed prior to releasing the vehicle or transmitter to the customer. All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or replacement of a transmitter battery using the following procedure. 1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of the unlock button, observe the battery gauge located in the upper right corner of the LCD display. The gauge should read full (three bars inside the battery icon). If after having a new battery installed, the battery goes dead within five months, the transmitter could have high sleep current, causing the battery to go dead. Replace the transmitter. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. Determine if Transmitter is in Second Vehicle Mode 1. Press and release any of the face buttons on the 2-way transmitter and observe the display on power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be displayed on the left side of the transmitter display. Is the 2-way transmitter in second vehicle mode? If Yes, the 2-way transmitter is working properly. - Press and release the left side button twice within one second. The 2-way transmitter should exit second vehicle mode. - Press and release the lock button. Press and release the unlock button. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 13925 - Confirm that the vehicle responds with the appropriate lock and unlock function. - If Yes , the 2-way transmitter was in mode B. - Press and release the left side button twice within one second. The 2-way transmitter should enter second vehicle mode. - Use the "next available slot" method in the scan tool to program the 2-way transmitter to the 2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI. - Both vehicle modes of the 2-way transmitter should now be coded to the vehicle. If No: The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal diagnostic procedures. Parts Information For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts Catalog or Corporate Bulletin Number 09-00-89-025A. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 13926 Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote Start INFORMATION Bulletin No.: 09-00-89-025A Date: October 26, 2009 Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT 2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent 2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA, OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY Attention: This bulletin does not apply to GMODC dealers. Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin Number 09-00-89-025 (Section 00 - General Information). This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems. Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 13927 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 13928 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 13929 Parts Information Service parts common to all 2-Way Advanced Remote Start Systems Transmitter Battery 12493150 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-52-001G > Aug > 10 > Keyless Entry - Intermittent/Inoperative Remote Keyless Entry Transmitter: Customer Interest Keyless Entry - Intermittent/Inoperative Remote TECHNICAL Bulletin No.: 08-08-52-001G Date: August 24, 2010 Subject: EI08028 - Intermittent, Inoperative Remote Keyless Entry (RKE) (Reprogram Key Fobs) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to change the labor operation number. Please discard Corporate Bulletin Number 08-08-52-001F (Section 08 - Body and Accessories). Condition Some customers may comment that one or more key fobs are inoperative. A number of warranty claims have been submitted that show relearning the key fobs has corrected this concern. Cause Based on technician feedback, engineering has determined two possible causes for key fob concerns: - The fobs may not be programmed when the vehicles leave the plant. - There may be Issues with the fobs internal components. Correction To correct the customer's concern, reprogram the transmitter (key fob). Refer to the procedure for Transmitter Programming found in Service Information. If reprogramming the transmitter is not successful, it will be necessary to replace the transmitter. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-08-52-001G > Aug > 10 > Keyless Entry - Intermittent/Inoperative Remote Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Intermittent/Inoperative Remote TECHNICAL Bulletin No.: 08-08-52-001G Date: August 24, 2010 Subject: EI08028 - Intermittent, Inoperative Remote Keyless Entry (RKE) (Reprogram Key Fobs) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to change the labor operation number. Please discard Corporate Bulletin Number 08-08-52-001F (Section 08 - Body and Accessories). Condition Some customers may comment that one or more key fobs are inoperative. A number of warranty claims have been submitted that show relearning the key fobs has corrected this concern. Cause Based on technician feedback, engineering has determined two possible causes for key fob concerns: - The fobs may not be programmed when the vehicles leave the plant. - There may be Issues with the fobs internal components. Correction To correct the customer's concern, reprogram the transmitter (key fob). Refer to the procedure for Transmitter Programming found in Service Information. If reprogramming the transmitter is not successful, it will be necessary to replace the transmitter. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 10-08-52-003 > Jul > 10 > Keyless Entry - Transmitter Button Inop/Won't Program Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter Button Inop/Won't Program INFORMATION Bulletin No.: 10-08-52-003 Date: July 21, 2010 Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to Vehicle Models: 2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007 Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade, Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express 2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry Attention: This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry (RKE) transmitter operation. This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may be inoperative intermittently or in which a particular button(s) does not work. To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are depressed longer than 30 seconds. The disabled button or buttons will remain disabled until another button that has not been disabled is pressed. If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed to a vehicle, press and release each and every button on the fob one at a time until you find one that works then retest the other buttons. If all buttons are now working, the button(s) were disabled and the transmitter is working as designed. If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics as shown in SI. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 10-08-52-003 > Jul > 10 > Keyless Entry - Transmitter Button Inop/Won't Program Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter Button Inop/Won't Program INFORMATION Bulletin No.: 10-08-52-003 Date: July 21, 2010 Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to Vehicle Models: 2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007 Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade, Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express 2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry Attention: This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry (RKE) transmitter operation. This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may be inoperative intermittently or in which a particular button(s) does not work. To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are depressed longer than 30 seconds. The disabled button or buttons will remain disabled until another button that has not been disabled is pressed. If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed to a vehicle, press and release each and every button on the fob one at a time until you find one that works then retest the other buttons. If all buttons are now working, the button(s) were disabled and the transmitter is working as designed. If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics as shown in SI. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Transmitter: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13954 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13955 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13956 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13957 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13958 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13959 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13960 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13961 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13962 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13963 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13964 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13965 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13966 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13967 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13968 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13969 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13970 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13971 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13972 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13973 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13974 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13975 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13976 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13977 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13978 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13979 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13980 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13981 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13982 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13983 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13984 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13985 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13986 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13987 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13988 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13989 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13990 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13991 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13992 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13993 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13994 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13995 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13996 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13997 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13998 Keyless Entry Transmitter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13999 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14000 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14001 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14002 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14003 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14004 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14005 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14006 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14007 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14008 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14009 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14010 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14011 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14012 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14013 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14014 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14015 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14016 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14017 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14018 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14019 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14020 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14021 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14022 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14023 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14024 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14025 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14026 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14027 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14028 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14029 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14030 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14031 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14032 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14033 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14034 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14035 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14036 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14037 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14038 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14039 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14040 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14041 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14042 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14043 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14044 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14045 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14046 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14047 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14048 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14049 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14050 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14051 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14052 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14053 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14054 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14055 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14056 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14057 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14058 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14059 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14060 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14061 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14062 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14063 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14064 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14065 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14066 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14067 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14068 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14069 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14070 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14071 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14072 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14073 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14074 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14075 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14076 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14077 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14078 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14079 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14080 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14081 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14082 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14083 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14084 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14085 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14086 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14087 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14088 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14089 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14090 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14091 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14092 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14093 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14094 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14095 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14096 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14097 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14098 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14099 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14100 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14101 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14102 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14103 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14104 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14105 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14106 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14107 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14108 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14109 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14110 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14111 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14112 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14113 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14114 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14115 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14116 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14117 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14118 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14119 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14120 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14121 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14122 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14123 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14124 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14125 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14126 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14127 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14128 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14129 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14130 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14131 Keyless Entry Transmitter: Electrical Diagrams Remote Function Schematics Keyless Entry Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Page 14132 Keyless Entry Transmitter: Tools and Equipment Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Diagrams Security Lamp/Indicator: Diagrams Component Connector End Views Security Indicator Lamp (SPO Alarm) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Shock Sensor, Antitheft > Component Information > Diagrams Shock Sensor: Diagrams Component Connector End Views Vehicle Shock Sensor (SPO Alarm) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Tow Sensor, Antitheft > Component Information > Diagrams Tow Sensor: Diagrams Component Connector End Views Vehicle Inclination Sensor (SPO Alarm) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-08-44-003B > Oct > 10 > Audio - Buzz Noise When Using Bluetooth(R) Cellular Phone Microphone: Customer Interest Audio - Buzz Noise When Using Bluetooth(R) TECHNICAL Bulletin No.: 10-08-44-003B Date: October 13, 2010 Subject: Buzz Noise During Call When Using Bluetooth(R) (Replace Microphone and Bezel) Models: 2009-2011 Buick Enclave, LaCrosse, Lucerne 2008-2011 Cadillac CTS, CTS-V 2009-2011 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT, SRX, STS (with RPO YQ1 or YQ2), XLR 2009-2010 Chevrolet Cobalt, Corvette, Equinox, HHR, Impala, Malibu, Silverado, Suburban, Tahoe, TrailBlazer, Traverse 2010-2011 Chevrolet Camaro 2009-2010 GMC Envoy 2009-2011 GMC Acadia, Sierra, Yukon, Yukon XL 2009-2010 Pontiac G5, G6, Solstice, Torrent 2009-2010 HUMMER H2, H3 2009-2010 Saturn AURA, OUTLOOK, SKY, VUE 2009 Saab 9-7X All Equipped with OnStar(R) (UE1) and Bluetooth (UPF) Supercede: This bulletin is being revised to replace the microphone and bezel (if needed) and update model years. Please discard Corporate Bulletin Number 10-08-44-003A (Section 08 - Body and Accessories). Condition Some customers may comment on a buzz noise (from the land-line side only) during a call. On any vehicle equipped with OnStar(R) (UE1) and Bluetooth(R) (UPF), an electromagnetic compatibility (EMC) buzz can be heard from the land-line side only of the phone during a Bluetooth(R) phone call made with an older model global system for mobile communications (GSM) phone. The buzz is only heard with older model GSM phones and is dependent on the distance of the phone from the microphone. The newer 3G GSM phones or other cellular phones (CDMA, TDMA, etc.) have not shown this concern. Correction Equipped with Headliner Microphone (Cobalt, HHR (non-sunroof) H2, H3) A new microphone and bezel has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Also replace the bezel. Refer to the parts information table below for correct color/part number. Equipped with Overhead Console Microphone Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-08-44-003B > Oct > 10 > Audio - Buzz Noise When Using Bluetooth(R) > Page 14151 A new microphone has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-08-44-003B > Oct > 10 > Audio - Buzz Noise When Using Bluetooth(R) Cellular Phone Microphone: All Technical Service Bulletins Audio - Buzz Noise When Using Bluetooth(R) TECHNICAL Bulletin No.: 10-08-44-003B Date: October 13, 2010 Subject: Buzz Noise During Call When Using Bluetooth(R) (Replace Microphone and Bezel) Models: 2009-2011 Buick Enclave, LaCrosse, Lucerne 2008-2011 Cadillac CTS, CTS-V 2009-2011 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT, SRX, STS (with RPO YQ1 or YQ2), XLR 2009-2010 Chevrolet Cobalt, Corvette, Equinox, HHR, Impala, Malibu, Silverado, Suburban, Tahoe, TrailBlazer, Traverse 2010-2011 Chevrolet Camaro 2009-2010 GMC Envoy 2009-2011 GMC Acadia, Sierra, Yukon, Yukon XL 2009-2010 Pontiac G5, G6, Solstice, Torrent 2009-2010 HUMMER H2, H3 2009-2010 Saturn AURA, OUTLOOK, SKY, VUE 2009 Saab 9-7X All Equipped with OnStar(R) (UE1) and Bluetooth (UPF) Supercede: This bulletin is being revised to replace the microphone and bezel (if needed) and update model years. Please discard Corporate Bulletin Number 10-08-44-003A (Section 08 - Body and Accessories). Condition Some customers may comment on a buzz noise (from the land-line side only) during a call. On any vehicle equipped with OnStar(R) (UE1) and Bluetooth(R) (UPF), an electromagnetic compatibility (EMC) buzz can be heard from the land-line side only of the phone during a Bluetooth(R) phone call made with an older model global system for mobile communications (GSM) phone. The buzz is only heard with older model GSM phones and is dependent on the distance of the phone from the microphone. The newer 3G GSM phones or other cellular phones (CDMA, TDMA, etc.) have not shown this concern. Correction Equipped with Headliner Microphone (Cobalt, HHR (non-sunroof) H2, H3) A new microphone and bezel has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Also replace the bezel. Refer to the parts information table below for correct color/part number. Equipped with Overhead Console Microphone Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-08-44-003B > Oct > 10 > Audio - Buzz Noise When Using Bluetooth(R) > Page 14157 A new microphone has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Page 14158 Cellular Phone Microphone: Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Page 14159 Cellular Phone Microphone: Diagrams Component Connector End Views Noise Compensation Microphone (UQA with Y91) Cellular Telephone Microphone (UE1, UUL or UUK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Page 14160 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Page 14161 Cellular Phone Microphone: Service and Repair Mobile Telephone Microphone Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired Communications Control Module: Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired > Page 14166 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired > Page 14167 Communications Control Module: Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired > Page 14168 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 14169 Communications Control Module: Locations Harness Routing Views I/P Extension Harness Routing (SLT except Y91/MEX) 1 - JX223 (U2K/UK6/UE1) 2 - X203 (UE1/U3U/UVB) 3 - X204 (U42) 4 - X212 5 - X206 (U42) 6 X213 (COAX) 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - X301 (UQA/D07) 9 Floor Panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 14170 Communications Control Module: Diagrams Component Connector End Views Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 14171 Vehicle Communication Interface Module (VCIM) X3 (UE1 with UUL or UUK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 14172 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement (with RPO SLT) Communications Control Module: Service and Repair Communication Interface Module Replacement (with RPO SLT) Communication Interface Module Replacement (with RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement (with RPO SLT) > Page 14175 Communications Control Module: Service and Repair Communication Interface Module Replacement (without RPO SLT) Communication Interface Module Replacement (without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Exterior View Display Module > Component Information > Diagrams Exterior View Display Module: Diagrams Component Connector End Views Rearview Camera Image Display Module X1 (UVC) Rearview Camera Image Display Module X2 (UVC) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Exterior View Display Module > Component Information > Diagrams > Page 14180 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams Parking Assist Control Module: Diagrams Component Connector End Views Rear Object Sensor Control Module X1 (UD7) Rear Object Sensor Control Module X2 (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams > Page 14184 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams > Page 14185 Parking Assist Control Module: Service and Repair Rear Object Alarm Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams Parking Assist Distance Sensor: Diagrams Component Connector End Views Object Alarm Sensor - Left Rear Corner (UD7) Object Alarm Sensor - Left Rear Middle (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 14189 Object Alarm Sensor - Right Rear Corner (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 14190 Object Alarm Sensor - Right Rear Middle (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 14191 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement Rear Object Sensor Replacement Removal Procedure 1. Disconnect electrical from the rear object sensor. 2. Lift the locking tabs on the housing and remove the rear object sensor. Installation Procedure Note: Do not refinish previously painted sensors. Excess paint build up will cause the sensor to be inoperative. 1. Paint the rear object sensor. Refer to Basecoat/Clearcoat Paint Systems (See: Body and Frame/Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems). 2. Ensure the paint does not exceed 6 mils. Use a paint thickness gauge suitable for non-ferrous metals. Refer to Paint Gauges (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14194 Note: Ensure the silicone decoupling ring is installed on the sensor to avoid sensor failure. 3. Insert the sensor into the housing. 4. Connect the electrical connector to the rear object sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14195 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (Sierra/Silverado) Rear Object Sensor Housing Replacement (Sierra/Silverado) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14196 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (All Other Vehicles) Rear Object Sensor Housing Replacement (All Other Vehicles) 1. Remove the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () or Rear Bumper Impact Bar End Cap Replacement (). 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. Important: Do Not grind off alignment tabs. 4. Sand/grind sonic weld plastic residue from the fascia. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14197 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14198 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () or Rear Bumper Impact Bar End Cap Replacement (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Service and Repair Parking Assist Warning Indicator: Service and Repair Information Center Telltale Assembly Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Diagrams Rear Vision Camera: Diagrams Component Connector End Views Rearview Camera (SPO Rearview Camera) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Diagrams > Page 14205 Rear Vision Camera: Service and Repair Rearview Camera Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver / Vehicle Information Display Switch > Component Information > Diagrams Driver / Vehicle Information Display Switch: Diagrams Component Connector End Views Driver Information Center (DIC) Switch (except MEX or 8S8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver / Vehicle Information Display Switch > Component Information > Service and Repair > Driver Information Display Switch Replacement (with RPO SLT) Driver / Vehicle Information Display Switch: Service and Repair Driver Information Display Switch Replacement (with RPO SLT) Driver Information Display Switch Replacement (with RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver / Vehicle Information Display Switch > Component Information > Service and Repair > Driver Information Display Switch Replacement (with RPO SLT) > Page 14211 Driver / Vehicle Information Display Switch: Service and Repair Driver Information Display Switch Replacement (without RPO SLT) Driver Information Display Switch Replacement (without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14220 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14226 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player Auxiliary Input / Output Jack: Technical Service Bulletins Audio - Information on USB/Multimedia Player INFORMATION Bulletin No.: 10-08-44-004A Date: November 11, 2010 Subject: Information on USB Command and Control Multimedia Player Interface/List of Supported Devices Models: 2011 Buick Regal 2010-2011 Cadillac SRX 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2011 Chevrolet Cruze, Equinox, Volt 2010-2011 GMC Terrain All Equipped with Convenience and Connectivity Package (RPOs UUK, UUL, UYS) Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 10-08-44-004 (Section 08 - Body and Accessories). USB Radio and MP3 Functionality The universal serial bus (USB) will be a USB 2.0 port on the radio faceplate, on the IP or in the center console. This interface will give the customer the additional functionality of iPod(R)/MP3 command and control. Customers now have full radio control of the iPod/MP3 audio files via the USB cable. A single USB connection allows digital audio transferring from the iPod to the radio. The iPod will be charging while connected to the radio. The customer will also have playback capability with a USB memory stick (only MP3 and WMA files). Note Not all memory sticks are supported. Note Video from the iPod is NOT capable of being transferred to a Navigation radio display. Problems with iPod Not Connecting If the infotainment system does not operate properly when using a device connected through the USB port, this may be due to an incompatible media device. Important DO NOT replace the radio or multimedia interface module due to a customer device incompatibility issue. Verify the customer's media device is validated for this system using the list below. If the customer's device is a validated device for this system, follow the SI diagnostic procedure to isolate the fault. If the customer's device is not on the validated device list, explain to the customer that their particular unit is not compatible with the system. Troubleshooting Tips for iPod Devices 1. Verify the version of the iPod/MP3 to confirm that it is supported. 2. Unplug and re-insert the iPod to verify the customer concern. 3. Verify the battery charge of the iPod. A low battery condition on the iPod may not allow it to connect to the radio. The iPod may need to be charged before it can be controlled by the radio. 4. If the customer receives a "Device Not Supported" message on their radio or is having general iPod/MP3 connection issues (and they have a supported device), they may need to reset their iPod. To reset the iPod: - For the iPod nano(R) and iPod classic(R), toggle the Hold switch on and off (slide it to Hold, then turn it off again). Press and hold the Menu and Center (Select) buttons simultaneously until the Apple(R) logo appears, about 6 to 8 seconds. You may need to repeat this step. - For the iPod touch(R) and iPhone(R): Press and hold the Sleep/Wake button for a few seconds until the red slider appears, then slide the slider. 5. For iPod touch and iPhone: To obtain full use capabilities of their device, it needs to be fully powered up when connecting to the USB port. If these devices are fully powered down or in "sleep" mode, please advise the customer to press and hold the Sleep/Wake button on the top of the device for a few seconds and if an unlock pass code is required, to enter the pass code as well as slide the lower "Unlock" slider. 6. Have the customer inspect their cable for quality. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14232 - Aftermarket cables can wear from use. The customer may need to purchase a new USB cable. - Verify that cable extensions are not present. The extra capacitance may cause too large a signal drop for the iPod to communicate with the radio. 7. If the customer receives a "Device Not Supported" message on their radio with an iPod connected (and they have a supported device), the customer may need to download the latest firmware from the Apple website (Please visit www.apple.com for more information). Validated Apple Device - Both Charge/Support Digital Audio Important None of these device lists below support video. Important Not all iPhone functions are fully supported. For further information on identifying iPod models, please visit http://support.apple.com/kb/HT1353. Important These devices (and additional MP3 players) may be capable of connecting to the other USB options by internally setting the MP3 device to mass storage class (MSC) mode. In this mode, the USB port will see the device as a flash drive. Please have the customer refer to their MP3 device manual on how to set the device to MSC. If the device is not able to be set to MSC, the customer must use the AUX jack. Note MTP mode must be used in order to transfer ANY Digital Rights Management (DRM) protected content. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14233 Non-Validated Apple Device Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14234 Playback Operation (X = Supported; - = Not Supported) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14235 Other USB Device Supported Requirements (X = Supported; - = Not Supported) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14236 Auxiliary Input / Output Jack: Technical Service Bulletins Audio System - USB/Multimedia Interface Information INFORMATION Bulletin No.: 09-08-44-013C Date: October 05, 2010 Subject: Information on USB Command and Control Multimedia Player Interface/List of Supported Devices Models: 2010-2011 Buick Enclave, LaCrosse 2008-2011 Cadillac CTS 2010-2011 Cadillac Escalade Models, SRX 2009-2010 Chevrolet Cobalt 2009-2011 Chevrolet HHR, Malibu 2010-2011 Chevrolet Avalanche, Camaro, Equinox, Silverado, Suburban, Tahoe, Traverse 2011 Chevrolet Cruze 2010-2011 GMC Acadia, Sierra, Terrain, Yukon 2009-2010 Pontiac G5, G6, Solstice, Solstice Coupe 2009-2010 Saturn AURA, SKY 2010 Saturn OUTLOOK All Equipped with Convenience and Connectivity Package - RPOs KTA, KTB, SRJ, U4H, UUI, UUJ, UUM, UUN, U2S, U2X, U2Y, UAV, UYZ, UY5 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-44-013B (Section 08 - Body and Accessories). USB Radio and MP3 Functionality The USB (Universal Serial Bus) will be a USB 2.0 port on the radio faceplate, on the IP or in the center console. This interface will give the customer the additional functionality of iPod/MP3 command and control. Customers now have full radio control of the iPod/MP3 audio files via the USB cable. A single USB connection allows digital audio transferring from the iPod to the radio. The customer will also have playback capability with a USB memory stick (only MP3 and WMA files). Note Not all memory sticks are supported. Customers have full radio control of the iPod/MP3 audio files via the USB cable. A single USB connection allows digital audio transferring from the iPod to the radio. The iPod will be charging while connected to the radio. Note Video from the iPod is NOT capable of being transferred to a Navigation radio display. For the Chevrolet Cobalt, HHR and Malibu; Pontiac G5, G6, Solstice; and Saturn AURA, SKY, the USB port is on the faceplate of the radio. For all other models, it is located in the center console or IP. For the Cadillac CTS only, a special iPod cable (USB and AUX cable) is needed. This special cable comes delivered with the vehicle. In all cases, the iPod will be charging while connected to the radio through the USB port when the vehicle is running or the RPA is active. Problems with iPod Not Connecting If the infotainment system does not operate properly when using a device connected through the USB port, this may be due to an incompatible media device. Important DO NOT replace the radio or multimedia interface module due to a customer device incompatibility issue. Verify the customer's media device is validated for this system using the list below. If the customer's device is a validated device for this system, follow the SI diagnostic procedure to isolate the fault. If the customer's device is not on the validated device list, explain to the customer that their particular unit is not compatible with the system. Troubleshooting Tips for iPod Devices Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14237 1. Check the version of the iPod/MP3 to confirm that it is supported. 2. Unplug and Re-insert the iPod to verify the customer complaint. 3. Verify the battery charge of the iPod. A low battery condition on the iPod may not allow it to connect to the radio. The iPod may need to be charged before it can be controlled by the radio. 4. If the customer receives a "Device Not Supported" message on their radio or is having general iPod/MP3 connection issues (and they have a supported device), they may need to reset their iPod. To reset the iPod: - For the iPod Nanos and Classic , Toggle the Hold switch on and off. (Slide it to Hold, then turn it off again. Press and hold the Menu and Center (Select) buttons simultaneously until the Apple logo appears, about 6 to 8 seconds. You may need to repeat this step. - For the iPod Touch and iPhone: Press and hold the Sleep/Wake button for a few seconds until the red slider appears, then slide the slider. 5. Have the customer check their cable for quality. - Aftermarket cables can wear from use. The customer may need to purchase a new USB cable. - Verify that cable extensions are not present. The extra capacitance may cause too large a signal drop for the iPod to communicate with the radio. 6. If the customer receives a "Device Not Supported" message on their radio with an iPod connected (and they have a supported device), the customer may need to download the latest firmware from the Apple website (Please visit www.apple.com for more information). Validated Apple Device - Both Charge/Support Digital Audio (For All RPOs) For further information on identifying iPod models, please visit http://support.apple.com/kb/ht1353 Other Validated Device- Both Charge/Support Digital Audio for Buick LaCrosse, Chevrolet Camaro, Equinox Only (RPO KTA or KTB) Important: Must be set to MTP (Mass Transfer Protocol) in the MP3 Player device setting. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14238 Important These devices (and additional MP3 players) may be capable of connecting to the other USB options by internally setting the MP3 device to MSC (Mass Storage Class) mode. In this mode, the USB port will see the device as a flash drive. Please have the customer refer to their MP3 device manual on how to set the device to MSC. If the device is not able to be set to MSC, the customer must use the AUX jack. Note MTP mode must be used in order to transfer ANY Digital Rights Management (DRM) protected content. Non-Validated Apple Device Important The devices above are NOT supported by USB interface. Apple does not support digital media transfer from these devices through the USB port. The customer can still listen to their older iPod on vehicle by connecting it to the Auxiliary Input Jack using a standard 3.5 mm (1/8 in) stereo cable. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14239 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Page 14240 Auxiliary Input / Output Jack: Diagrams Component Connector End Views Audio/Video Adapter (U42) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Service and Repair > USB Receptacle Replacement (With SLT) Auxiliary Input / Output Jack: Service and Repair USB Receptacle Replacement (With SLT) USB Receptacle Replacement (With SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Service and Repair > USB Receptacle Replacement (With SLT) > Page 14243 Auxiliary Input / Output Jack: Service and Repair USB Receptacle Replacement (Without SLT) USB Receptacle Replacement (Without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams Television / Monitor: Diagrams Component Connector End Views Digital Video Disc (DVD) Display - Driver Seat Headrest X1 (SPO DVD) Digital Video Disc (DVD) Display - Driver Seat Headrest X2 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Page 14247 Digital Video Disc (DVD) Display - Passenger Seat Headrest X1 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Page 14248 Digital Video Disc (DVD) Display - Passenger Seat Headrest X2 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Page 14249 Video Display (U42) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Page 14250 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Page 14251 Television / Monitor: Service and Repair Video Display Replacement (Second Row) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams DVD Player: Diagrams Component Connector End Views Digital Video Disc (DVD) Control Module X1 (SPO DVD) Digital Video Disc (DVD) Control Module X2 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 14255 Digital Video Disc (DVD) Control Module X3 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 14256 Digital Video Disc (DVD) Control Module X4 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 14257 Digital Video Disc (DVD) Control Module X5 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 14258 Digital Video Disc (DVD) Control Module X6 (SPO DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 14259 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Specifications Garage Door Opener Transmitter: Specifications Fastener Tightening Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions Garage Door Opener Transmitter: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14265 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14266 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14267 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14268 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14269 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14270 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14271 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14272 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14273 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14274 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14275 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14276 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14277 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14278 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14279 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14280 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14281 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14282 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14283 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14284 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14285 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14286 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14287 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14288 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14289 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14290 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14291 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14292 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14293 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14294 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14295 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14296 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14297 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14298 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14299 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14300 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14301 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14302 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14303 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14304 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14305 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14306 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14307 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14308 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14309 Garage Door Opener Transmitter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14310 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14311 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14312 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14313 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14314 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14315 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14316 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14317 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14318 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14319 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14320 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14321 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14322 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14323 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14324 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14325 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14326 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14327 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14328 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14329 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14330 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14331 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14332 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14333 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14334 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14335 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14336 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14337 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14338 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14339 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14340 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14341 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14342 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14343 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14344 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14345 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14346 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14347 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14348 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14349 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14350 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14351 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14352 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14353 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14354 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14355 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14356 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14357 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14358 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14359 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14360 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14361 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14362 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14363 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14364 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14365 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14366 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14367 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14368 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14369 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14370 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14371 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14372 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14373 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14374 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14375 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14376 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14377 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14378 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14379 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14380 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14381 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14382 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14383 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14384 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14385 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14386 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14387 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14388 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14389 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14390 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14391 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14392 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14393 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14394 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14395 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14396 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14397 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14398 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14399 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14400 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14401 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14402 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14403 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14404 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14405 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14406 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14407 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14408 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14409 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14410 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14411 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14412 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14413 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14414 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14415 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14416 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14417 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14418 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14419 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14420 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14421 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14422 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14423 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14424 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14425 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14426 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14427 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14428 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14429 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14430 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14431 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14432 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14433 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14434 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14435 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14436 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14437 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14438 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14439 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14440 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14441 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14442 Garage Door Opener Transmitter: Connector Views Component Connector End Views Garage Door Opener (GDO) (UG1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14443 Garage Door Opener Transmitter: Electrical Diagrams Remote Function Schematics Garage Door Opener Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Page 14444 Garage Door Opener Transmitter: Description and Operation Garage Door Opener Description and Operation The garage door opener (GDO) is fixed and rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the GDO to change every time the GDO is used within operating range of the receiver. Rolling code programming requires the customer to push a learn/program button on the GDO receiver at their home. This button is usually located on the receiver unit under a cover (light cover) on one end of the unit. The customer must follow the GDO manufacturers instructions to program/learn the receiver to accept the Universal Home Remote System as an authorized opener for their unit. When the receiver and the GDO are initially programmed together, a code is established and a new code is created for every new transmission. The software in the receiver recognizes the GDO and accepts the new code. The GDO is compatible with most, but not all types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, refer to 1-866-572-2728. The GDO is a transmitter operating between 288-399 MHz. The power and range of the transmitter is limited to comply with laws governing the generation of radio frequency interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitters. The GDO has 3 buttons that may be programmed for individual transmitter/receiver combinations to control up to 3 GDOs, security gates, lighting systems, etc. Each button represents a transmitter code section of the transmitter, which operates separately from any other button, and may be considered a separate transmitter. Operation consists of simply pressing a button to activate the corresponding transmitter. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures Symptoms - Remote Functions Symptoms - Remote Functions Important: The following steps must be completed before using the symptom tables. 1. Perform Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle) before using the Symptom Tables in order to verify that all of the following are true: * There are no DTCs set. * The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Keyless Entry System Description and Operation (with Accessory 2 Way Remote) (See: Antitheft and Alarm Systems/Keyless Entry/Description and Operation/Keyless Entry System (with Accessory 2 Way Remote))Keyless Entry System Description and Operation (without Accessory 2 Way Remote) (See: Antitheft and Alarm Systems/Keyless Entry/Description and Operation/Keyless Entry System (without Accessory 2 Way Remote)). Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the Keyless Entry System. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Garage Door Opener Inoperative (See: Garage Door Opener Inoperative) * Keyless Entry System Inoperative (See: Antitheft and Alarm Systems/Keyless Entry/Testing and Inspection/Symptom Related Diagnostic Procedures/Keyless Entry System Inoperative) * Remote Vehicle Start Inoperative (See: Antitheft and Alarm Systems/Keyless Entry/Testing and Inspection/Symptom Related Diagnostic Procedures/Remote Vehicle Start Inoperative) Garage Door Opener Inoperative Garage Door Opener Inoperative Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The garage door opener (GDO) is a transmitter operating between 288 and 399 MHz. The GDO has three buttons that may be programmed for individual transmitter/receiver combinations to control up to three GDOs, security gates, lighting systems, etc. Each button represents a unique transmitter code section, which operates independently of the other buttons, and may be considered a separate transmitter. Reference Information Schematic Reference Remote Function Schematics (See: Diagrams/Electrical Diagrams) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 14447 Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Garage Door Opener Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools J 41540 Universal Home Remote Tester Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the GDO. 2. Ignition OFF, test for less than 5 ohm between the ground circuit terminal 3 and ground. ‹› If greater than the specified value, test the ground circuit for an open/high resistance. 3. Ignition ON, verify a test lamp illuminates between the B+ circuit terminal 1 and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. Important: This step will clear any learned transmitters from the GDO. This will require reprogramming by the customer to reestablish GDO functionality. 4. Ignition ON, hold the two outer buttons on the GDO for 30 seconds. After 20 seconds, the LEDs will flash indicating that all learned transmitter values have been cleared. After an additional 10 seconds, the LEDs will flash again indicating it has entered the diagnostic mode. Place the J 41540 adjacent to the GDO and press each button of the GDO one at a time. The tester should indicate when each button is pressed. ‹› If the tester indicates that one or more of the buttons does not respond, replace the GDO. 5. Instruct the customer to program the GDO. Refer to the vehicle owners manual. A possible rolling code or incompatibility with the GDO receiver will prevent programming. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Control Module References (See: Testing and Inspection/Programming and Relearning) for GDO replacement, setup, and programming Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 14448 Garage Door Opener Transmitter: Programming and Relearning Garage Door Opener Programming - Universal Important: Do not use the garage door opener (GDO) with any garage door opener that does not have the stop and reverse safety feature. This includes any garage door opener model manufactured before April 1, 1982. Ensure that people and objects are clear of the garage door while performing programming operations. Programming the GDO for Rolling Code Receivers Important: If the programming procedure is unsuccessful, it may be necessary to perform the Erasing Channels procedure first. This procedure will learn a rolling code garage door opener to the GDO transmitter. The learn process must be completed within 30 seconds. 1. Press the two outside buttons of the GDO for one to two seconds, then immediately release them. 2. Locate the "Learn" or "Smart" button on the garage door opener receiver (located on the garage door opener motor-head unit). It is often found where the hanging antenna wire is attached to the motor-head unit and may be a colored button. Refer to the garage door opener operator's manual or call 1-866-572-2728 for assistance. Press the "Learn" or "Smart" button. The garage door opener operator's manual may provide assistance in determining when the unit is in learn mode. 3. Immediately return to the GDO transmitter in the vehicle. Press and hold the button that is to be learned; the LED above the button will begin to flash slowly. When the garage door moves, immediately release the button. The LED will flash rapidly until programming is complete. 4. Press the button used during the learn operation again in order to verify that the GDO transmitter has been programmed. The GDO is compatible with most, but not all, types of garage door openers. If the GDO LED does not flash rapidly after 90 seconds, there may be a compatibility conflict with the garage door opener. Call 1-866-572-2728 to address compatibility concerns. Programming the GDO for Fixed Code Receivers Important: If the programming procedure is unsuccessful, it may be necessary to perform the Erasing Channels procedure first. This procedure will learn a fixed code garage door opener to the GDO transmitter. To determine if the customer has a fixed code garage door opener, remove the battery cover on the customer supplied transmitter. If a row of dip switches is present, the garage door opener is a fixed code version. The transmitter should have anywhere from 8 to 12 switches. The garage door opener receiver may also have a set of dip switches. If the number of switches on the receiver and the transmitter do not match, use the receiver switches to program the GDO. Each dip switch may have either two or three positions. The two position switch can either be ON or OFF. The three position switch can either be ON, NEUTRAL, or OFF. 1. Write down the positions of the dip switches. The positions of the switches will be entered from left to right into the GDO using the three buttons. 2. Press all three buttons on the GDO for three seconds and immediately release them. The LEDs should flash slowly, indicating that the GDO is in programming mode. 3. Enter the positions of the dip switches one at a time. If a position of a dip switch is on, press the left button on the GDO. If the position is neutral, press the middle button of the GDO. If the position is off, press the right button of the GDO. Enter all of the positions of the dip switches. The procedure must be completed in two and a half minutes. 4. After entering all of the switch positions, firmly press and release all three buttons at the same time. The indicator lights will turn on. 5. Press and hold the button that is to be learned; the LED above the button will begin to flash slowly. When the garage door moves, immediately release the button. The LED will flash rapidly until programming is complete. 6. Press the button used during the learn operation again in order to verify that the GDO transmitter has been programmed. The GDO is compatible with most, but not all, types of garage door openers. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the garage door opener. Call 1-866-572-2728 to address compatibility concerns. Erasing Channels To erase programmed channels, press and hold the two outside buttons until the lights on the GDO transmitter begins to flash. Once the LEDs begin to flash, release both buttons; all learned codes are now erased. Individual channels cannot be erased, but can be reprogrammed using the procedures above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Page 14449 Garage Door Opener Transmitter: Service and Repair Garage Door Opener Transmitter Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Global Positioning System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14458 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Global Positioning System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14464 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired Global Positioning System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 14469 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired Global Positioning System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 14475 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Memory Positioning Module: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14480 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14481 Memory Positioning Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14482 Memory Seat Module (MSM) X3 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14483 Memory Seat Module (MSM) X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14484 Memory Seat Module (MSM) X5 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14485 Memory Seat Module (MSM) X6 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14486 Memory Seat Module (MSM) X7 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14487 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14488 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Seat Memory Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 14492 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 14493 Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14502 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-44-034E > Feb > 11 > Navigation Radio - Various Noises Explained Navigation System: All Technical Service Bulletins Navigation Radio - Various Noises Explained INFORMATION Bulletin No.: 06-08-44-034E Date: February 11, 2011 Subject: Information on Noise Sources from Navigation Radio - CD/DVD Disc Accessing Noise from Radio Fan, for Cooling, Disc Accessing Noise for Navigation Operation or NAV Traffic Information Models: 2008-2011 Buick Enclave 2007-2009 Cadillac SRX 2007-2011 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2007-2009 HUMMER H2 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 06-08-44-034D (Section 08 - Body and Accessories). Some customers may comment that there are unusual fan type noises coming from the navigation radio. Additionally, the customer may comment on radio noise coming from the CD/DVD or MAP disc mechanisms when CDs/DVDs or MAP discs are present in the CD mechanisms. Some customers have mentioned that radio noise is present when the customer enters the vehicle or that the noise continues after they shut the vehicle off and open the door to leave the vehicle. This noise has been described as a fan sound or hearing a disc spinning. Source of fan sound - It is normal for the radio fan to run when the vehicle is turned on and for up to three minutes after the vehicle has been turned off and the driver's door has been opened or closed. Disc spinning sound - This is a normal operational sound. This is caused by the map disc spinning behind the tilt screen. It is a normal operation after the RKE is used to unlock the vehicle or when the driver's door has been opened. This noise will also be heard during vehicle operation and up to three minutes after the vehicle has been turned off and driver's door has been opened and closed. MAP Disc Accessing "ZIP" sound - As the Navigation Radio accesses the MAP Disc, the customer may describe frequent "zip" type noises. This noise is caused by the CD Read Lens moving across the disc to access needed data for proper MAP display. To determine if the source of the noise is from accessing the MAP Disc, remove the MAP Disc to determine if the noise continues. With the addition of the Real Time NAV Traffic Feature, the MAP CD may be accessed to a greater extent thus resulting in additional MAP Drive noise. Inform the customer about these noises. If the customer believes the noise is not normal, compare the condition to a like vehicle with identical settings to determine if there is a noticeable difference. Do not replace the radio as the described conditions are normal operating characteristics. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14512 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-44-006 > Oct > 10 > Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-44-012E > Apr > 10 > Navigation System Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-44-012E > Apr > 10 > Navigation System Software/DVD Update Program > Page 14521 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired Navigation System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 14526 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) Navigation System: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) > Page 14531 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 14537 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 14538 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 14539 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 14545 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 14546 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 14547 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor > Component Information > Service and Repair Pedal Positioning Sensor: Service and Repair Brake and Accelerator Pedal Adjuster Position Sensor Replacement (With Memory Seats) Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Disconnect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Remove the adjustable pedal position sensor bolts (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor > Component Information > Service and Repair > Page 14552 5. Remove the brake and accelerator pedal adjuster position sensor (1). Installation Procedure 1. Install the brake and accelerator pedal adjuster position sensor (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor > Component Information > Service and Repair > Page 14553 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the adjustable pedal position sensor bolts (1) and tighten to 2 Nm (18 lb in). 3. Connect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Install the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams Amplifier: Diagrams Component Connector End Views Audio Amplifier X1 (UQA with Y91) Audio Amplifier X1 (UQA without Y91) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 14558 Audio Amplifier X2 (UQA) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 14559 Audio Amplifier X3 (UQA) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 14560 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 14561 Amplifier: Service and Repair Radio Speaker Amplifier Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Automatic Volume Control > System Information > Service and Repair Automatic Volume Control: Service and Repair Radio Volume Compensator Interior Noise Microphone Replacement (Floor Console) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Radio/Stereo Noise Filter: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 14574 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Radio/Stereo Noise Filter: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 14580 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams Remote Switch: Diagrams Component Connector End Views Rear Seat Audio (RSA) Control X1 (UK6) Rear Seat Audio (RSA) Control X2 (UK6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 14584 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams Speaker: Diagrams Component Connector End Views Speaker - Center I/P (UQA with Y91) Speaker - Left Front (UQ3) Speaker - Left Front (UQ5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 14588 Speaker - Left Front (UQA) Speaker - Left Front Tweeter (except MEX) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 14589 Speaker - Left Rear (Extended Cab or Crew Cab with UQ3 or UQ5) Speaker - Left Rear (Extended Cab or Crew Cab with UQA) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 14590 Speaker - Left Rear (Regular Cab) Speaker - Right Front (UQ3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 14591 Speaker - Right Front (UQ5) Speaker - Right Front (UQA) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 14592 Speaker - Right Front Tweeter (except MEX) Speaker - Right Rear (Extended Cab or Crew Cab with UQ3 or UQ5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 14593 Speaker - Right Rear (Extended Cab or Crew Cab with UQA) Speaker - Right Rear (Regular Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 14594 Speaker - Subwoofer (UQA) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement Speaker: Service and Repair Front Upper Speaker Replacement Front Upper Speaker Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14597 Speaker: Service and Repair Radio Front Floor Console Speaker Replacement Radio Front Floor Console Speaker Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14598 Speaker: Service and Repair Radio Front Side Door Speaker Replacement Radio Front Side Door Speaker Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14599 Speaker: Service and Repair Radio Front Speaker Grille Replacement Radio Front Speaker Grille Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14600 Speaker: Service and Repair Front Upper Speaker Replacement Front Upper Speaker Replacement Radio Front Floor Console Speaker Replacement Radio Front Floor Console Speaker Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14601 Radio Front Side Door Speaker Replacement Radio Front Side Door Speaker Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14602 Radio Front Speaker Grille Replacement Radio Front Speaker Grille Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14603 Radio Front Speaker Replacement Radio Front Speaker Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14604 Radio Rear Side Door Speaker Replacement (Crew Cab) Radio Rear Side Door Speaker Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14605 Radio Rear Side Door Speaker Replacement (Extended Cab) Radio Rear Side Door Speaker Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14606 Rear Pillar Speaker Replacement Rear Pillar Speaker Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14607 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams Alarm Module: Diagrams Component Connector End Views Theft Deterrent Module (TDM) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 14612 Alarm Module: Service and Repair Theft Deterrent Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) Availability for Hearing Impaired Communications Control Module: Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) Availability for Hearing Impaired > Page 14617 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) Availability for Hearing Impaired > Page 14618 Communications Control Module: Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) Availability for Hearing Impaired > Page 14619 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 14620 Communications Control Module: Locations Harness Routing Views I/P Extension Harness Routing (SLT except Y91/MEX) 1 - JX223 (U2K/UK6/UE1) 2 - X203 (UE1/U3U/UVB) 3 - X204 (U42) 4 - X212 5 - X206 (U42) 6 X213 (COAX) 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - X301 (UQA/D07) 9 Floor Panel Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 14621 Communications Control Module: Diagrams Component Connector End Views Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 14622 Vehicle Communication Interface Module (VCIM) X3 (UE1 with UUL or UUK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 14623 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement (with RPO SLT) Communications Control Module: Service and Repair Communication Interface Module Replacement (with RPO SLT) Communication Interface Module Replacement (with RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement (with RPO SLT) > Page 14626 Communications Control Module: Service and Repair Communication Interface Module Replacement (without RPO SLT) Communication Interface Module Replacement (without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14635 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14641 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams Parking Assist Control Module: Diagrams Component Connector End Views Rear Object Sensor Control Module X1 (UD7) Rear Object Sensor Control Module X2 (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 14648 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 14649 Parking Assist Control Module: Service and Repair Rear Object Alarm Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14658 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14659 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14660 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14666 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14667 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14668 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14677 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14678 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14679 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 14685 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 14686 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 14687 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams Parking Assist Distance Sensor: Diagrams Component Connector End Views Object Alarm Sensor - Left Rear Corner (UD7) Object Alarm Sensor - Left Rear Middle (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 14695 Object Alarm Sensor - Right Rear Corner (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 14696 Object Alarm Sensor - Right Rear Middle (UD7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 14697 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement Rear Object Sensor Replacement Removal Procedure 1. Disconnect electrical from the rear object sensor. 2. Lift the locking tabs on the housing and remove the rear object sensor. Installation Procedure Note: Do not refinish previously painted sensors. Excess paint build up will cause the sensor to be inoperative. 1. Paint the rear object sensor. Refer to Basecoat/Clearcoat Paint Systems (See: Body and Frame/Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems). 2. Ensure the paint does not exceed 6 mils. Use a paint thickness gauge suitable for non-ferrous metals. Refer to Paint Gauges (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14700 Note: Ensure the silicone decoupling ring is installed on the sensor to avoid sensor failure. 3. Insert the sensor into the housing. 4. Connect the electrical connector to the rear object sensor. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14701 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (Sierra/Silverado) Rear Object Sensor Housing Replacement (Sierra/Silverado) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14702 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (All Other Vehicles) Rear Object Sensor Housing Replacement (All Other Vehicles) 1. Remove the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () or Rear Bumper Impact Bar End Cap Replacement (). 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. Important: Do Not grind off alignment tabs. 4. Sand/grind sonic weld plastic residue from the fascia. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14703 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14704 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () or Rear Bumper Impact Bar End Cap Replacement (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair Pedal Positioning Sensor: Service and Repair Brake and Accelerator Pedal Adjuster Position Sensor Replacement (With Memory Seats) Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Disconnect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Remove the adjustable pedal position sensor bolts (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair > Page 14708 5. Remove the brake and accelerator pedal adjuster position sensor (1). Installation Procedure 1. Install the brake and accelerator pedal adjuster position sensor (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair > Page 14709 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the adjustable pedal position sensor bolts (1) and tighten to 2 Nm (18 lb in). 3. Connect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Install the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams Remote Switch: Diagrams Component Connector End Views Rear Seat Audio (RSA) Control X1 (UK6) Rear Seat Audio (RSA) Control X2 (UK6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 14713 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Shock Sensor, Antitheft > Component Information > Diagrams Shock Sensor: Diagrams Component Connector End Views Vehicle Shock Sensor (SPO Alarm) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Steering Mounted Controls Assembly > Component Information > Service and Repair Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Tow Sensor, Antitheft > Component Information > Diagrams Tow Sensor: Diagrams Component Connector End Views Vehicle Inclination Sensor (SPO Alarm) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Assembly > Component Information > Service and Repair Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams Steering Mounted Controls Transmitter: Diagrams Component Connector End Views Steering Wheel Control Switch - Left (K34 or KA9) Steering Wheel Control Switch - Right (UK3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 14729 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement (1500/2500 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 14738 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 14739 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 14740 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 14741 Trailer Brake Control Module: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 14742 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 14743 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 14744 Trailer Brake Control Module: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 except 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 14745 Trailer Brake Control Module (JL1 with 31 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 14746 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 14747 Fuel Pump/Trailer Brake Control Module (Gas with JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 14748 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 14749 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement > Page 14752 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement (1500) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: The trailer brake control module is integral to the fuel pump flow control module. 2. Remove the fuel pump flow control module (1). Refer to Fuel Pump Flow Control Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement > Page 14753 1. Install the fuel pump flow control module (1). Refer to Fuel Pump Flow Control Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. If installing a new trailer brake control module, program the module. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controllers Trailer Connector: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controllers > Page 14758 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controllers > Page 14759 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Technical Service Bulletins > Page 14760 Trailer Connector: Diagrams Component Connector End Views Trailer Connector (except MEX or EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) Trailer Hitch: Service and Repair Trailer Hitch Replacement (Light Duty) Trailer Hitch Replacement (Light Duty) Removal Procedure 1. Disconnect the trailer wiring harness connector (3) from the trailer wiring receptacle (4). 2. Remove the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 3. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 4. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 5. Remove the hitch platform bolts (6) from the frame weld nuts (2). 6. Remove the hitch platform from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 14765 1. Position the hitch platform to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 Nm (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 Nm (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 Nm (74 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 14766 5. Install the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 6. Connect the trailer wiring harness connector (3) to the trailer wiring receptacle (4). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 14767 Trailer Hitch: Service and Repair Trailer Hitch Replacement (Heavy Duty) Trailer Hitch Replacement (Heavy Duty) Removal Procedure 1. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 2. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 3. Remove the hitch platform bolts (6) from the frame weld nuts (2). 4. Remove the hitch platform from the vehicle. Installation Procedure 1. Position the hitch platform to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 14768 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 Nm (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 Nm (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 Nm (74 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 14772 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 14773 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 14774 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 14775 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 14776 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 14777 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 14778 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 14779 Trailer Lighting Relay: Diagrams Component Connector End Views Trailer Stop/Turn Relay (TZ0) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Diagrams Trailer Towing Relay: Diagrams Component Connector End Views Trailer Brake Control Relay (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Diagrams > Page 14783 Trailer Towing Relay: Service and Repair Trailer Brake Control Relay Replacement (1500) Removal Procedure 1. Turn the ignition switch to the OFF position. Note: Do not remove the spare tire and wheel hoist. 2. Remove the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair). 3. Disconnect the trailer brake control relay electrical connector. Note: It is not necessary to completely remove the bolts. 4. Loosen, but do not remove, the trailer brake control relay bolts (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Diagrams > Page 14784 5. Slide the trailer brake control relay (1) toward the center of the vehicle and remove the trailer brake control relay. Installation Procedure 1. If installing a new trailer brake control relay, hand start the 2 trailer brake control relay bolts. 2. Position the trailer brake control relay to the frame bracket. 3. Slide the trailer brake control relay (1) toward the left frame rail. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Diagrams > Page 14785 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the trailer brake control relay bolts (1) to 6 Nm (53 lb in). 5. Connect the trailer brake control relay electrical connector. 6. Install the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controllers Trailer Connector: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controllers > Page 14790 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controllers > Page 14791 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Technical Service Bulletins > Page 14792 Trailer Connector: Diagrams Component Connector End Views Trailer Connector (except MEX or EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 14812 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 14818 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 14819 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 14820 Body Control Module (BCM) X2 Body Control Module (BCM) X3 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 14821 Body Control Module (BCM) X4 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 14822 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 14823 Body Control Module (BCM) X5 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 14824 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 14825 Body Control Module (BCM) X6 Body Control Module (BCM) X7 (except MEX or A52) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 14826 Auxiliary Body Control Module (XBCM) X1 (EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 14827 Auxiliary Body Control Module (XBCM) X2 (EXP) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 14828 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 14831 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 14832 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 14833 Body Control Module: Service and Repair Serial Data Gateway Module Replacement Serial Data Gateway Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair Auxiliary Step / Running Board: Service and Repair Assist Step Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Center Support Bracket Replacement Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Center Support Bracket Replacement Front Bumper Fascia Center Support Bracket Replacement (GMC) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Center Support Bracket Replacement > Page 14843 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Side Bracket Replacement Front Bumper Fascia Side Bracket Replacement (GMC) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Center Support Bracket Replacement > Page 14844 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Outer Support Replacement Front Bumper Fascia Outer Support Replacement (GMC) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Adjustments Front Bumper Reinforcement: Adjustments Front Bumper Impact Bar Adjustment (Chevrolet) 1. Remove the right or left front wheelhouse liners. Refer to Front Wheelhouse Liner Replacement Right Side (Chevrolet) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side) and Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 2. Loosen the inner front bumper impact bar support bolts (1). 3. Loosen the outer front bumper impact bar support bolts (2). 4. Position a service jack to the front bumper impact bar support (3) to raise the front bumper impact bar if needed. 5. Push downward on the end of the front bumper impact bar (4) to lower if needed. 6. Align the front bumper impact bar (4) in order to achieve and equal gap to the lower edge of the headlamp and fender. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Tighten the inner front bumper impact bar support bolts (1) to 55 Nm (40 lb ft). 8. Tighten the outer front bumper impact bar support bolts (1) to 55 Nm (40 lb ft). 9. Install the right or left front wheelhouse liners. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side) and Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Impact Bar Replacement Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Replacement Front Bumper Impact Bar Replacement (Chevrolet) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Impact Bar Replacement > Page 14850 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Outer Bracket Replacement Front Bumper Impact Bar Outer Bracket Replacement (Chevrolet) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Impact Bar Replacement > Page 14851 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Extension Replacement (Chevrolet) Front Bumper Impact Bar Extension Replacement (Chevrolet) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Impact Bar Replacement > Page 14852 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Extension Replacement Front Bumper Impact Bar Extension Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Impact Bar Replacement > Page 14853 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Brace Replacement Front Bumper Impact Bar Brace Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Rear Bumper Impact Bar Replacement Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Replacement Rear Bumper Impact Bar Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Rear Bumper Impact Bar Replacement > Page 14859 Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Brace Replacement Rear Bumper Impact Bar Brace Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48))Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48))Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Regular Cab)) 2. Remove the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) ( See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)) 3. Pull back carpeting on the rear wall of the cab exposing the pressure relief valve. 4. Press on the retaining tab on the top downward to release the valve from the cab back panel. 5. Remove the pressure relief valve from the vehicle. Installation Procedure 1. Align the pressure relief valve into the opening of the rear cab. 2. Press the pressure relief valve into the cab back panel until the locking tabs are fully seated. 3. Realign carpeting on the rear wall of the cab to lay flat. 4. Install the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) ( See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)) 5. Install the rear window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48))Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48))Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Regular Cab)) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked Front Door Exterior Handle: Customer Interest Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked > Page 14879 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked Front Door Exterior Handle: All Technical Service Bulletins Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked > Page 14885 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Exterior Handle: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Exterior Handle: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 14891 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Exterior Handle: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 14892 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Exterior Handle: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 14893 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Exterior Handle: > Page 14894 Front Door Exterior Handle: By Symptom Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Exterior Handle: > Page 14895 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Exterior Handle: > Page 14896 Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Exterior Handle: > Page 14897 Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Page 14898 Front Door Exterior Handle: Service and Repair Front Side Door Outside Handle Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Front Side Door Inside Handle Replacement (with SLT) Front Door Interior Handle: Service and Repair Front Side Door Inside Handle Replacement (with SLT) Front Side Door Inside Handle Replacement (with SLT) Removal Procedure 1. Remove door upper trim panel. Refer to Upper Extension Trim Panel Replacement (See: Front Door Panel/Service and Repair). 2. Pull the door trim panel away from the door and support the bottom of the trim panel on the door panel hooks. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Front Door Panel/Service and Repair)Front Side Door Trim Panel Replacement (Except YE9 or SLT) ( See: Front Door Panel/Service and Repair). 3. Remove the front side door inside handle fasteners (1). 4. Remove the front side door inside handle assembly (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Front Side Door Inside Handle Replacement (with SLT) > Page 14903 1. Disconnect the electrical connector. 2. If replacing the door handle, transfer the heated seat switch or seat adjuster memory switch, if equipped. Refer to Front Seat Heater Switch Replacement (See: Seats/Seat Heater Switch/Service and Repair/Front Seat Heater Switch Replacement) or Driver Seat Adjuster Memory Switch Replacement (Crew Cab) (See: Mirrors/Memory Positioning Systems/Seat Memory Switch/Service and Repair). 3. Depress both tabs to remove the front side door cable and pull the cable rearward out of the handle assembly. Installation Procedure 1. Connect the front side door cable. Ensure the cable is fully seated past the guide tab. 2. Slide the front side door inside handle assembly into place (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the front side door inside handle fasteners and tighten to 2 Nm (18 lb in). 4. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Front Door Panel/Service and Repair)Front Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Front Side Door Inside Handle Replacement (with SLT) > Page 14904 Door Trim Panel Replacement (Except YE9 or SLT) (See: Front Door Panel/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Front Side Door Inside Handle Replacement (with SLT) > Page 14905 Front Door Interior Handle: Service and Repair Front Side Door Inside Handle Replacement (without SLT) Front Side Door Inside Handle Replacement (without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair Front Door Hinge: Service and Repair Front Side Door Upper Hinge and Lower Hinge Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Page 14909 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams Front Door Latch: Diagrams Component Connector End Views Door Latch - Driver (AU3) Door Latch - Driver (except AU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 14913 Door Latch - Left Rear (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 14914 Door Latch - Passenger Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 14915 Door Latch - Right Rear (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 14916 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement Front Door Panel: Service and Repair Front Side Door Window Switch Bezel Replacement Front Side Door Window Switch Bezel Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 14921 Front Door Panel: Service and Repair Front Side Door Pull Handle Replacement Front Side Door Pull Handle Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 14922 Front Door Panel: Service and Repair Front Side Door Trim Panel Replacement (Slt, A95) Front Side Door Trim Panel Replacement (SLT, A95) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 14923 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 14924 Front Door Panel: Service and Repair Front Side Door Trim Panel Replacement (Except YE9 or Slt) Front Side Door Trim Panel Replacement (Except YE9 or SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 14925 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 14926 Front Door Panel: Service and Repair Front Side Door Window Switch Bezel Replacement Front Side Door Window Switch Bezel Replacement Front Side Door Pull Handle Replacement Front Side Door Pull Handle Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 14927 Front Side Door Trim Panel Replacement (Slt, A95) Front Side Door Trim Panel Replacement (SLT, A95) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 14928 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 14929 Front Side Door Trim Panel Replacement (Except YE9 or Slt) Front Side Door Trim Panel Replacement (Except YE9 or SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 14930 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 14931 Upper Extension Trim Panel Replacement Upper Extension Trim Panel Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 14932 Front Side Door Water Deflector Replacement Front Side Door Water Deflector Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 14933 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments Door Lock Striker Adjustment To determine if striker adjustment is required, proceed as follows: 1. Make certain the door is properly aligned within the door opening before proceeding with the striker adjustment. 2. Close the door onto the striker and note if the door drags on the striker causing the door to move upward or downward upon contact with the striker. Also note the closing effort to fully engage the latch. 3. Using a soft marker, mark around the striker for reference of the original position. Loosen the striker. 4. Move the striker to eliminate drag on the striker and door latch and to achieve the proper door position within the door opening. Start with the up/down position, then position the striker to achieve proper alignment to the door opening. Set the in/out adjustment for the proper door seal engagement making sure the door closing efforts are correct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the striker-to-body bolts to 27 Nm (20 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement (Crew Cab) Front Door Striker: Service and Repair Door Striker Replacement (Crew Cab) Door Striker Replacement (Crew Cab) Removal Procedure Note: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the lower striker bolt. 2. Loosen the upper striker bolt enough in order to rotate the striker and the spacer, if equipped, away from the lower bolt hole. 3. Install the lower striker bolt. Tighten the lower striker bolt sufficiently in order to hold the striker backing plate in place. 4. Remove the upper striker bolt (1). 5. Remove the spacer, if equipped. 6. Remove the striker (2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement (Crew Cab) > Page 14939 1. Install the striker. 2. Install the spacer, if equipped. 3. Install the upper striker bolt (1). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. 5. Remove the lower bolt. 6. Rotate the striker (2) and the spacer, if equipped, in order to align the lower threaded hole in the striker backing plate. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Tighten the striker bolts. Tighten the door striker bolts to 24 Nm (18 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement (Crew Cab) > Page 14940 Front Door Striker: Service and Repair Door Striker Replacement (Extended Cab, Lower) Door Striker Replacement (Extended Cab Lower) Removal Procedure Note: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the door lower striker bolts (1). 2. Remove the spacer, if equipped. 3. Remove the door lower striker (2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement (Crew Cab) > Page 14941 1. Install the door lower striker (2). 2. Install the spacer, if equipped. 3. Install the door lower striker bolt (1). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the lower striker bolts. Tighten the door lower striker bolts to 24 Nm (18 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement (Crew Cab) > Page 14942 Front Door Striker: Service and Repair Door Striker Replacement (Extended Cab, Upper) Door Striker Replacement (Extended Cab Upper) Removal Procedure Note: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the upper trim door upper striker cover (2). Pull straight downward for the trim cover to release, retained by retainer clips (1). 2. Remove the door upper striker bolts (3). 3. Remove the spacer, if equipped. 4. Remove the door upper striker (4). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement (Crew Cab) > Page 14943 1. Install the door upper striker (4). 2. Install the spacer, if equipped. 3. Install the door upper striker bolt (3). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the upper striker bolts. Tighten the door upper striker bolts to 24 Nm (18 lb ft). 6. Install the upper trim door upper striker cover. Ensure that the retainer clips were Not damaged when removed. Push upward into locator holes. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 14952 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 06-08-64-035G > Jun > 10 > Body - Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 14962 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 06-08-64-035G > Jun > 10 > Body - Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement Front Door Weatherstrip: Service and Repair Front Side Door Window Weatherstrip Replacement Front Side Door Window Weatherstrip Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 14969 Front Door Weatherstrip: Service and Repair Front Side Door Roof Drip Weatherstrip Replacement Front Side Door Roof Drip Weatherstrip Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 14970 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Regular Cab) Front Door Opening Weatherstrip Replacement (Regular Cab) Removal Procedure 1. Remove the front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)). 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 14971 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 14972 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Extended Cab) Front Door Opening Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Open both doors. 2. Remove the front and rear door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)) or Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 3. Remove the hinge pillar trim. Refer to Body Hinge Pillar Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Hinge Pillar Trim Panel Replacement). 4. Remove the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) ( See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)). 5. Remove the windshield pillar molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 6. Remove the weatherstrip (1) from the pinch-weld flange (2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 14973 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Install the weatherstrip (1) to the pinch-weld flange (2). Ensure that the weatherstrip is fully seated around the door opening. 3. Install the windshield pillar molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 4. Install the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) ( See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)). 5. Install the hinge pillar trim. Refer to Body Hinge Pillar Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Hinge Pillar Trim Panel Replacement). 6. Install the sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)) or Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 7. Inspect the door closing effort and seal to door fit. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 14974 Front Door Weatherstrip: Service and Repair Front Side Door Bottom Auxiliary Sealing Strip Replacement Front Side Door Bottom Auxiliary Sealing Strip Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise Front Door Window Glass: Customer Interest Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise > Page 14983 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise Front Door Window Glass: All Technical Service Bulletins Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise > Page 14989 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information > Page 14998 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information > Page 15008 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 15009 Front Door Window Glass: By Symptom Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 15010 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 15011 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Page 15012 Front Door Window Glass: Service and Repair Front Side Door Window Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams Front Door Window Motor: Diagrams Component Connector End Views Window Motor - Driver (A31) Window Motor - Passenger (A31) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Page 15016 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Page 15017 Front Door Window Motor: Service and Repair Front Side Door Window Regulator Motor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise Front Door Window Regulator: Customer Interest Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise > Page 15026 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise Front Door Window Regulator: All Technical Service Bulletins Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise > Page 15032 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 15033 Front Door Window Regulator: By Symptom Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 15034 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 15035 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement Front Door Window Regulator: Service and Repair Door Window Regulator Handle Replacement Door Window Regulator Handle Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 15038 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement (Manual) Front Side Door Window Regulator Replacement (Manual) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 15039 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement (Power) Front Side Door Window Regulator Replacement (Power) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Rear Door Exterior Handle: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked Rear Door Exterior Handle: Customer Interest Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Rear Door Exterior Handle: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked > Page 15050 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked Rear Door Exterior Handle: All Technical Service Bulletins Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked > Page 15056 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > Page 15057 Rear Door Exterior Handle: By Symptom Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > Page 15058 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > Page 15059 Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > Page 15060 Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Side Door Outside Handle Replacement (Crew Cab) Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Replacement (Crew Cab) Rear Side Door Outside Handle Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Side Door Outside Handle Replacement (Crew Cab) > Page 15063 Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Replacement (Extended Cab) Rear Side Door Outside Handle Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Side Door Inside Handle Replacement (with SLT) Rear Door Interior Handle: Service and Repair Rear Side Door Inside Handle Replacement (with SLT) Rear Side Door Inside Handle Replacement (with SLT) Removal Procedure 1. Pull the door trim panel away from the door and support the bottom of the trim panel on the door panel hooks. Refer to Rear Side Door Trim Panel Replacement (SLT) (See: Rear Door Panel/Service and Repair/Rear Side Door Trim Panel Replacement (SLT))Rear Side Door Trim Panel Replacement (YE9) (See: Rear Door Panel/Service and Repair/Rear Side Door Trim Panel Replacement (YE9)). 2. Remove the rear side door inside handle fasteners (1). 3. Remove the rear side door inside handle fasteners assembly (2). 1. Disconnect the electrical connector. 2. Depress both tabs to remove the rear side door cable and pull the cable rearward out of the handle assembly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Side Door Inside Handle Replacement (with SLT) > Page 15068 Installation Procedure 1. Connect the rear side door cable. Ensure the cable is fully seated past the guide tab. 2. Slide the rear side door inside handle assembly into place (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the rear side door inside handle fasteners and tighten to 2 Nm (18 lb in). 4. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement (SLT) (See: Rear Door Panel/Service and Repair/Rear Side Door Trim Panel Replacement (SLT))Rear Side Door Trim Panel Replacement (YE9) (See: Rear Door Panel/Service and Repair/Rear Side Door Trim Panel Replacement (YE9)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Side Door Inside Handle Replacement (with SLT) > Page 15069 Rear Door Interior Handle: Service and Repair Rear Side Door Inside Handle Replacement (without SLT) Rear Side Door Inside Handle Replacement (without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Door Hinge Cover Replacement Rear Door Hinge: Service and Repair Rear Side Door Hinge Cover Replacement Rear Side Door Hinge Cover Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Door Hinge Cover Replacement > Page 15074 Rear Door Hinge: Service and Repair Rear Side Door Upper Hinge and Lower Hinge Replacement (Crew Cab) Rear Side Door Upper Hinge and Lower Hinge Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Door Hinge Cover Replacement > Page 15075 Rear Door Hinge: Service and Repair Rear Side Door Upper Hinge and Lower Hinge Replacement (Extended Cab) Rear Side Door Upper Hinge and Lower Hinge Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Door Hinge Cover Replacement > Page 15076 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams Rear Door Latch: Diagrams Component Connector End Views Door Latch - Driver (AU3) Door Latch - Driver (except AU3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 15080 Door Latch - Left Rear (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 15081 Door Latch - Passenger Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 15082 Door Latch - Right Rear (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 15083 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) Rear Door Panel: Service and Repair Rear Side Door Window Switch Bezel Replacement (Crew Cab) Rear Side Door Window Switch Bezel Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15088 Rear Door Panel: Service and Repair Rear Side Door Window Switch Bezel Replacement (Extended Cab) Rear Side Door Window Switch Bezel Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15089 Rear Door Panel: Service and Repair Rear Side Door Trim Panel Replacement (SLT) Rear Side Door Trim Panel Replacement (SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15090 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15091 Rear Door Panel: Service and Repair Rear Side Door Trim Panel Replacement (YE9) Rear Side Door Trim Panel Replacement (YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15092 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15093 Rear Door Panel: Service and Repair Rear Side Door Window Switch Bezel Replacement (Crew Cab) Rear Side Door Window Switch Bezel Replacement (Crew Cab) Rear Side Door Window Switch Bezel Replacement (Extended Cab) Rear Side Door Window Switch Bezel Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15094 Rear Side Door Trim Panel Replacement (SLT) Rear Side Door Trim Panel Replacement (SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15095 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15096 Rear Side Door Trim Panel Replacement (YE9) Rear Side Door Trim Panel Replacement (YE9) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15097 Rear Side Access Door Trim Panel Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15098 Rear Side Access Door Trim Panel Replacement Rear Side Door Water Deflector Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15099 Rear Side Door Water Deflector Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments Rear Door Striker: Adjustments Door Lock Striker Adjustment To determine if striker adjustment is required, proceed as follows: 1. Make certain the door is properly aligned within the door opening before proceeding with the striker adjustment. 2. Close the door onto the striker and note if the door drags on the striker causing the door to move upward or downward upon contact with the striker. Also note the closing effort to fully engage the latch. 3. Using a soft marker, mark around the striker for reference of the original position. Loosen the striker. 4. Move the striker to eliminate drag on the striker and door latch and to achieve the proper door position within the door opening. Start with the up/down position, then position the striker to achieve proper alignment to the door opening. Set the in/out adjustment for the proper door seal engagement making sure the door closing efforts are correct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the striker-to-body bolts to 27 Nm (20 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments > Page 15103 Rear Door Striker: Service and Repair Door Striker Replacement (Crew Cab) Removal Procedure Note: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the lower striker bolt. 2. Loosen the upper striker bolt enough in order to rotate the striker and the spacer, if equipped, away from the lower bolt hole. 3. Install the lower striker bolt. Tighten the lower striker bolt sufficiently in order to hold the striker backing plate in place. 4. Remove the upper striker bolt (1). 5. Remove the spacer, if equipped. 6. Remove the striker (2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments > Page 15104 1. Install the striker. 2. Install the spacer, if equipped. 3. Install the upper striker bolt (1). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. 5. Remove the lower bolt. 6. Rotate the striker (2) and the spacer, if equipped, in order to align the lower threaded hole in the striker backing plate. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Tighten the striker bolts. Tighten the door striker bolts to 24 Nm (18 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 15113 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-64-035G > Jun > 10 > Body Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 15123 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-64-035G > Jun > 10 > Body - Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle Sound Proofing / Insulation: All Technical Service Bulletins Interior - Excessive Wind Noise In Interior Of Vehicle TECHNICAL Bulletin No.: 10-08-58-001E Date: March 08, 2011 Subject: Excessive Wind Noise Coming from Rear Interior of Vehicle (Perform Repair as Outlined) Models: 2007-2011 Chevrolet Silverado Crew Cab and Extended Cab 2007-2011 GMC Sierra Crew Cab and Extended Cab Supercede: This bulletin is being revised to update the repair in the Customer Enthusiasm section and update the Parts Information. Please discard Corporate Bulletin Number 10-08-58-001D (Section 08 - Body and Accessories). Condition Some customers may comment on hearing excessive wind noise coming from the rear interior of the vehicle. Cause #1 This condition may be caused by a void in the body filler within the C-pillar. Cause #2 This condition may be caused by the body rear panel acoustic insulator that is mounted behind the rear seat. There is an access flap (1) in this panel that could cause excessive noise if the flap is not fully seated/closed into the rest of the insulator material. Also, starting in 2010, a new insulator was installed that may allow higher wind/road or other acoustic noise that may be objectionable for some customers. Noise penetration into the cab can be higher than a similarly equipped 2009, or earlier, model. As shown in the graphic above, note that the service part insulator (1) is noticeably thicker than the original 2010 part (2). Correction #1 Note This repair is specific to 2007-2010 model years. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 15133 Important Prior to attempting a repair of the vehicle, it will be necessary to compare it to a like vehicle in similar operating characteristics to determine if it should be considered normal operation or a repairable condition. 1. To properly diagnose the C-pillar body filler issue, complete the following steps: 1. Close the all doors and windows of the vehicle. 2. Without starting the vehicle, turn the vehicle ignition to the ON/RUN position. 3. Press the HVAC selector switch for Outside Air. 4. Turn the HVAC Fan Control to Medium/High. Note The air flow that is felt most commonly exits the lower C-pillar opening shown in the graphic above. 5. Run your hand alongside the lower seam of the body at the base of the C-pillar and feel for air flowing out of the bottom of the body. 6. Compare the air flow on the opposite side of the vehicle. If one side exhibits a distinct higher amount of air flow, continue on to the next step in this procedure to start the process of adding sealer to the C-pillar on that side. If no air flow difference is found, skip ahead to Correction #2. 2. To access the inner C-pillar, remove the rear seat and the body lock pillar trim panel. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Figure 1 - Outside View Through C-pillar Figure 2 - Top View, Section Cut Through C-pillar 3. Inspect the inner baffle/foam within the C-pillar for any voids in the body filler. The examples above show an opening (1) in the baffle at the forward, inboard corner of the right side C-pillar. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 15134 4. If a void is found (1), fill it with seam sealer Kent Automotive High-Tech(TM) Clear Sealer, P/N P10200 (5 oz. tube), or equivalent, to eliminate the air flow escape concern. 5. Before reinstalling the trim, inspect the insulator mat that is mounted on the body rear inner panel to ensure the access flap is fully seated/closed as shown above. 6. Reinstall the trim panels and rear seat. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Correction #2 Note This repair is ONLY for 2010 models that have the original body rear panel insulator (pictured above) and exhibit a higher noise penetration into the cab, when compared to a similarly equipped 2009, or earlier, model. Note that the insulator shape is flat across the bottom edge. Tip Before any repairs, you can visually verify which insulator the vehicle has by looking under the rear seat on the right or left side. If you can see the body Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 15135 color of the rear inner panel (shown circled above) below the insulator (1), the insulator is the original design, which is trimmed straight across the bottom. Order a service body rear panel insulator (pictured above), referencing the parts table below. Note that the new insulator has an increased thickness and the height was extended on both ends. R & R the rear seat and any necessary trim to replace the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Further Repair for Customer Enthusiasm Only in situations when the above repairs are completed and the customer is still commenting on objectionable noise, the following additional steps can be done to sound-proof the body rear panel. This additional sound-proofing should only be done in cases deemed necessary for customer enthusiasm. Note After this procedure has been performed, the vehicle needs to be re-assembled and evaluated with the trim and rear seat fully installed in the vehicle. If the bulletin has been followed properly, the noise should be reduced to a level quieter than stock 2011 models, and no further repairs should be attempted. It has been found that controlling the wind noise at the two pressure relief valve (PRV) locations is the key to quieting the rear cab wind noise. The repair below has been found to be successful in eliminating most of the objectionable noise. 1. R & R the rear seat and any necessary trim to remove the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Note GM P/N 12378195 is not available in Canada. However several equivalents such as *Evercoat (Q-Pads) P/N 100116 and *Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. 2. Install noise and vibration sound deadening pads to backside of the body rear panel insulator. Follow the pattern shown above, ensuring they cover the two PRV locations. Use GM P/N 12378195, or equivalents commercially available through *Dynamat(R), Evercoat(R) or Dominion Sure Seal. Important Ensure that the foam tape pattern does not have any gaps in the corners and that it is securely pressed/attached to the inner rear body panel. 3. Install *Duck Brand Weatherstrip Seal (Self Adhesive Foam) P/N 1278750, or equivalent, to the inner body rear end panel following the patterns shown below: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 15136 Note Ensure that the cross-car adhesive foam is positioned at a height just below the insulator push pin fastener locations so that once the fasteners are installed, the seal is compressed. - Across the inner rear body panel, matching the width of the insulator panel. - Downward from each end of the cross-car foam (left side (1) shown in the graphic above). The length should match the height of the insulator panel. - Partially around the two PRV's. Install the foam down the outboard side (1), underneath (2), partially back up the inboard side (3), then finish with a length extending further inboard (4) from the PRV. Important Ensure that any C-pillar wiring harnesses/connectors are routed forward of the insulator, and not trapped behind it. 4. Position the body rear panel insulator to the inner rear body panel and install the push pin retainers. Caution should be taken to not disturb the foam tape installed previously. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 15137 Important Ensure that the foam is securely wedged between the outboard edges of the insulator and the wiring harnesses/sheet metal, making sure that any C-pillar wiring harnesses/connectors are routed forward of the insulator and foam, and not trapped behind either of them. 5. Install a length of *Duck Brand Window Air Conditioner Insulating Strip Seal P/N 1284075, or equivalent, down each side C-pillar. 6. Complete the installation of the insulator panel and interior trim. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Contact Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Duck Brand products, or equivalent, can be obtained from your local hardware or home improvement store. *GM‹›P/N‹›12378195 is not available in Canada. However several equivalents such as Evercoat (Q-Pads) P/N 100116 and Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 can be obtained by contacting Dominion Sure Seal at 1-800-265-0790. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 15143 Important Prior to attempting a repair of the vehicle, it will be necessary to compare it to a like vehicle in similar operating characteristics to determine if it should be considered normal operation or a repairable condition. 1. To properly diagnose the C-pillar body filler issue, complete the following steps: 1. Close the all doors and windows of the vehicle. 2. Without starting the vehicle, turn the vehicle ignition to the ON/RUN position. 3. Press the HVAC selector switch for Outside Air. 4. Turn the HVAC Fan Control to Medium/High. Note The air flow that is felt most commonly exits the lower C-pillar opening shown in the graphic above. 5. Run your hand alongside the lower seam of the body at the base of the C-pillar and feel for air flowing out of the bottom of the body. 6. Compare the air flow on the opposite side of the vehicle. If one side exhibits a distinct higher amount of air flow, continue on to the next step in this procedure to start the process of adding sealer to the C-pillar on that side. If no air flow difference is found, skip ahead to Correction #2. 2. To access the inner C-pillar, remove the rear seat and the body lock pillar trim panel. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Figure 1 - Outside View Through C-pillar Figure 2 - Top View, Section Cut Through C-pillar 3. Inspect the inner baffle/foam within the C-pillar for any voids in the body filler. The examples above show an opening (1) in the baffle at the forward, inboard corner of the right side C-pillar. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 15144 4. If a void is found (1), fill it with seam sealer Kent Automotive High-Tech(TM) Clear Sealer, P/N P10200 (5 oz. tube), or equivalent, to eliminate the air flow escape concern. 5. Before reinstalling the trim, inspect the insulator mat that is mounted on the body rear inner panel to ensure the access flap is fully seated/closed as shown above. 6. Reinstall the trim panels and rear seat. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Correction #2 Note This repair is ONLY for 2010 models that have the original body rear panel insulator (pictured above) and exhibit a higher noise penetration into the cab, when compared to a similarly equipped 2009, or earlier, model. Note that the insulator shape is flat across the bottom edge. Tip Before any repairs, you can visually verify which insulator the vehicle has by looking under the rear seat on the right or left side. If you can see the body Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 15145 color of the rear inner panel (shown circled above) below the insulator (1), the insulator is the original design, which is trimmed straight across the bottom. Order a service body rear panel insulator (pictured above), referencing the parts table below. Note that the new insulator has an increased thickness and the height was extended on both ends. R & R the rear seat and any necessary trim to replace the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Further Repair for Customer Enthusiasm Only in situations when the above repairs are completed and the customer is still commenting on objectionable noise, the following additional steps can be done to sound-proof the body rear panel. This additional sound-proofing should only be done in cases deemed necessary for customer enthusiasm. Note After this procedure has been performed, the vehicle needs to be re-assembled and evaluated with the trim and rear seat fully installed in the vehicle. If the bulletin has been followed properly, the noise should be reduced to a level quieter than stock 2011 models, and no further repairs should be attempted. It has been found that controlling the wind noise at the two pressure relief valve (PRV) locations is the key to quieting the rear cab wind noise. The repair below has been found to be successful in eliminating most of the objectionable noise. 1. R & R the rear seat and any necessary trim to remove the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Note GM P/N 12378195 is not available in Canada. However several equivalents such as *Evercoat (Q-Pads) P/N 100116 and *Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. 2. Install noise and vibration sound deadening pads to backside of the body rear panel insulator. Follow the pattern shown above, ensuring they cover the two PRV locations. Use GM P/N 12378195, or equivalents commercially available through *Dynamat(R), Evercoat(R) or Dominion Sure Seal. Important Ensure that the foam tape pattern does not have any gaps in the corners and that it is securely pressed/attached to the inner rear body panel. 3. Install *Duck Brand Weatherstrip Seal (Self Adhesive Foam) P/N 1278750, or equivalent, to the inner body rear end panel following the patterns shown below: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 15146 Note Ensure that the cross-car adhesive foam is positioned at a height just below the insulator push pin fastener locations so that once the fasteners are installed, the seal is compressed. - Across the inner rear body panel, matching the width of the insulator panel. - Downward from each end of the cross-car foam (left side (1) shown in the graphic above). The length should match the height of the insulator panel. - Partially around the two PRV's. Install the foam down the outboard side (1), underneath (2), partially back up the inboard side (3), then finish with a length extending further inboard (4) from the PRV. Important Ensure that any C-pillar wiring harnesses/connectors are routed forward of the insulator, and not trapped behind it. 4. Position the body rear panel insulator to the inner rear body panel and install the push pin retainers. Caution should be taken to not disturb the foam tape installed previously. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 15147 Important Ensure that the foam is securely wedged between the outboard edges of the insulator and the wiring harnesses/sheet metal, making sure that any C-pillar wiring harnesses/connectors are routed forward of the insulator and foam, and not trapped behind either of them. 5. Install a length of *Duck Brand Window Air Conditioner Insulating Strip Seal P/N 1284075, or equivalent, down each side C-pillar. 6. Complete the installation of the insulator panel and interior trim. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Contact Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Duck Brand products, or equivalent, can be obtained from your local hardware or home improvement store. *GM‹›P/N‹›12378195 is not available in Canada. However several equivalents such as Evercoat (Q-Pads) P/N 100116 and Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 can be obtained by contacting Dominion Sure Seal at 1-800-265-0790. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Opening Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15150 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15151 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15152 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15153 Rear Door Weatherstrip: Service and Repair Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15154 Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Opening Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15155 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15156 Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15157 Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15158 Rear Side Door Window Weatherstrip Replacement (Crew Cab) Rear Side Door Window Weatherstrip Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15159 Rear Side Door Window Weatherstrip Replacement (Extended Cab) Rear Side Door Window Weatherstrip Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15160 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Rear Side Door Window Replacement (Crew Cab) Rear Door Window Glass: Service and Repair Rear Side Door Window Replacement (Crew Cab) Rear Side Door Window Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Rear Side Door Window Replacement (Crew Cab) > Page 15165 Rear Door Window Glass: Service and Repair Rear Side Door Window Replacement (Extended Cab) Rear Side Door Window Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Side Door Window Regulator Replacement (Crew Cab, Manual) > Page 15170 Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Crew Cab, Power) Rear Side Door Window Regulator Replacement (Crew Cab, Power) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Side Door Window Regulator Replacement (Crew Cab, Manual) > Page 15171 Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Extended Cab, Power) Rear Side Door Window Regulator Replacement (Extended Cab, Power) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair Fuel Door: Service and Repair Fuel Tank Filler Door Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Hood Link Replacement Hood Hinge: Service and Repair Hood Link Replacement Hood Link Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Hood Link Replacement > Page 15180 Hood Hinge: Service and Repair Hood Hinge Replacement Hood Hinge Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Hood Link Replacement > Page 15181 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair Hood Insulator / Pad: Service and Repair Hood Insulator Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair Hood Latch: Service and Repair Hood Primary and Secondary Latch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Primary Latch Release Cable Replacement Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Replacement Hood Primary Latch Release Cable Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Primary Latch Release Cable Replacement > Page 15192 Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Handle Replacement Hood Primary Latch Release Cable Handle Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair > Hood Open Assist Spring Replacement Hood Shock / Support: Service and Repair Hood Open Assist Spring Replacement Hood Open Assist Spring Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair > Hood Open Assist Spring Replacement > Page 15197 Hood Shock / Support: Service and Repair Hood Strut Replacement Hood Strut Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair > Hood Stop Bracket Replacement Hood Stop: Service and Repair Hood Stop Bracket Replacement Hood Stop Bracket Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair > Hood Stop Bracket Replacement > Page 15202 Hood Stop: Service and Repair Hood Stop Bumper Bracket Replacement Hood Stop Bumper Bracket Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair > Hood Stop Bracket Replacement > Page 15203 Hood Stop: Service and Repair Hood Bumper Replacement Hood Bumper Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement Hood Weatherstrip: Service and Repair Hood Front Seal Replacement Hood Front Seal Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement > Page 15212 Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement Hood Rear Seal Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Binding In many cases, applying the proper lubrication can correct the following conditions: * Binding or sticking door lock cylinders * Difficulty in inserting and removing the keys For lubricating the above components, use lubricant GM P/N 12346241 or equivalent. Do not use penetrating lubricants such as GM P/N 1052949 or WD-40(R). Penetrating lubricants wash out the original lubrication. Penetrating lubricants eventually evaporate, leaving little or no lubricating material. However, when using penetrating lubricants in order to thaw or in order to loosen the lock cylinder components, refer to steps 2-4 in the procedure below for the proper methods of lubrication. Repair lock cylinders frozen in cold weather by using the following procedure: 1. While carefully avoiding damage to the painted surfaces, apply heat to the cylinder with a heat gun. 2. Using a paper clip or a similar item, hold the door shutter open. Force air into the cylinders using compressed air through a blow gun attachment. 3. While holding the shutter door open, inject small amounts of a recommended lubricant into the cylinder. 4. Work the key into the cylinder repeatedly. Wipe away any excess lubrication from the key. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (L71) Endgate Emblem/Nameplate Replacement (Z71) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15222 Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (Silverado) Endgate Emblem/Nameplate Replacement (Silverado) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15223 Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (LT LS) Endgate Emblem/Nameplate Replacement (LT LS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15224 Body Emblem: Service and Repair Hood Emblem/Nameplate Replacement (Vortec) Hood Emblem/Nameplate Replacement (Vortec) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15225 Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (L71) Endgate Emblem/Nameplate Replacement (Z71) Endgate Emblem/Nameplate Replacement (Silverado) Endgate Emblem/Nameplate Replacement (Silverado) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15226 Endgate Emblem/Nameplate Replacement (LT LS) Endgate Emblem/Nameplate Replacement (LT LS) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15227 Hood Emblem/Nameplate Replacement (Vortec) Hood Emblem/Nameplate Replacement (Vortec) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15228 Front Side Door Emblem/Nameplate Replacement (Chevrolet Silverado) Front Side Door Emblem/Nameplate Replacement (Chevrolet Silverado) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15229 Endgate Emblem/Nameplate Replacement (Chevrolet) Endgate Emblem/Nameplate Replacement (Chevrolet) Endgate Emblem/Nameplate Replacement (TUF) Endgate Emblem/Nameplate Replacement (TUF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15230 Radiator Grille Emblem/Nameplate Replacement (HD) Radiator Grille Emblem/Nameplate Replacement (Chevrolet HD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15231 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair Upper Side Moulding / Trim: Service and Repair Body Panel Paint Protector Replacement (VGC) 1. The paint protective film and vehicle surface temperature should be 13-32°C (55-90°F) for best results. 2. Automatic car washes should be avoided for at least 24 hours after the paint protective film application. 3. Wipe the vehicle surface with isopropyl alcohol or flash naptha at the application area. 4. Dry the surface with a clean lint-free cloth. 5. Create a mixture of 25 percent isopropyl alcohol and 75 percent water and two drops of baby shampoo per 16 oz of fluid mixture. 6. Remove the backing liner from the protective film patch. 7. Use the solution to liberally spray the adhesive side of the protective patch, the mounting location along with your hands. 8. Position the paint protective film patch to the desired location on the vehicle. 9. Spray the surface of the film with the alcohol, water and soap solution. 10. Using a dampened squeegee, start at the center of the protective patch, working outward in order to remove the air and solution from under the protective patch. 11. Release any air bubbles with a pin. 12. Dry the surface with a clean, lint-free cotton cloth. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: Customer Interest Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 15246 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 15247 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 15248 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: All Technical Service Bulletins Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 15254 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 15255 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 15256 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Front Wheelhouse Liner Replacement - Right Side Front Fender Liner: Service and Repair Front Wheelhouse Liner Replacement - Right Side Front Wheelhouse Liner Replacement - Right Side (Chevrolet) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Front Wheelhouse Liner Replacement - Right Side > Page 15263 Front Fender Liner: Service and Repair Front Wheelhouse Liner Replacement - Left Side Front Wheelhouse Liner Replacement - Left Side (Chevrolet) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 06-08-61-003F > Apr > 11 > Body/Frame - Underbody Pop/Clunk When Turning Body / Frame Mount Bushing: Customer Interest Body/Frame - Underbody Pop/Clunk When Turning TECHNICAL Bulletin No.: 06-08-61-003F Date: April 12, 2011 Subject: Underbody Pop or Clunk Type Noise While Turning or Driving on Uneven Road Surfaces (Install Body Mount Insulator) Models: 2004-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2004-2012 Chevrolet Avalanche, Silverado (Classic), Silverado, Suburban, Tahoe 2004-2012 GMC Sierra (Classic), Sierra Denali (Classic), Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-61-003E (Section 08 - Body and Accessories). Condition Some customers may comment on a pop or clunk type noise while turning or driving on uneven road surfaces. This noise can be heard and/or felt at either the driver's or front passenger floor pan area. Cause Under certain conditions, normal movement between the frame and the #1, #2 or #3 body mounts may cause this noise to occur. Diagnosis 1. If the vehicle is equipped with aftermarket (non-GM Accessory) running boards or the running board is mounted using the body mount bolt, remove the running boards prior to test driving the vehicle. This will eliminate the running boards as the possible cause of the noise. 2. Install the J-39570 Chassis Ears to the frame rail at or near the body mounts. 3. Test drive the vehicle to identify which mount is suspect. Correction Install an insulator at the suspect mount(s). The insulator should be installed between the upper portion of the body mount and the frame bracket. The #1 mount is the mount located just under the A-pillar. The #2 mount is the mount located just under the B-pillar. The #3 mount is the mount located just under the C-pillar. Use the procedure listed below. 1. Raise the vehicle on the hoist. It is recommended to use a four-post lift or strap the vehicle frame to the hoist arms. 2. For the left side mounts only, remove the intermediate park brake cable. Perform the following steps: 1. Remove the nut from the park brake equalizer. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 3. Remove all of the body mount bolts on the side being repaired. 4. Properly support the body at the body mount area. Caution When you remove the body mount, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 06-08-61-003F > Apr > 11 > Body/Frame - Underbody Pop/Clunk When Turning > Page 15273 5. Lower the chassis accordingly in order to remove the upper portion of the body mount. 6. Install the new insulator to the bottom of the top portion of the body mount. The picture shows the insulator (1) location after the body mount is reassembled. 7. Install the body mount to the frame bracket. 8. Perform the following procedure before installing the bolts. 1. Clean the bolt threads of all the original thread locking compound. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker, GM P/N 89021297 (In Canada, use P/N 10953488). 9. Install the body mount bolts. Tighten For 2003, 2004 and 2005 model year, tighten the bolts to 85 Nm (63 lb ft). Tighten For 2006-2012 model year, tighten the bolts to 100 Nm (74 lb ft). 10. Reinstall the intermediate park brake cable (left side only). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body Body Mount Bolt Stripped or Will Not Loosen Body / Frame Mount Bushing: Customer Interest Body - Body Mount Bolt Stripped or Will Not Loosen INFORMATION Bulletin No.: 10-08-61-001A Date: February 16, 2011 Subject: Information on Body Mount Bolt Stripped or Will Not Loosen Models: 2010-2011 Chevrolet Silverado 2010-2011 GMC Sierra Supercede: This bulletin is being revised to add Warranty Information. Please discard Corporate Bulletin Number 10-08-61-001 (Section 08 - Body and Accessories). The purpose of this bulletin is to provide guidance to GM dealers when performing repairs that involve the removal of the body mount bolts. Technicians may discover that one of the cab mount bolts won't loosen from the vehicle. The bolt may act like the nut is cross-threaded or no longer secured to the floorpan of the vehicle. The cab mounted cage nut may have bent or broken loose allowing the nut to spin. If the nut is allowed to spin, it may prevent the bolt from loosening. The front cab mount nuts are welded to the body structure and are not involved with this bulletin. The cage nut assembly must be accessed from inside of the vehicle if this condition occurs. Some of the cage nuts have rectangular access plates in the floor of the passenger compartment. These plates are located above the affected bolt. On extended cab vehicles it is necessary to create access holes in the rear floor area to reach the rear cage nut. Creating Access Hole (Extended Cab Vehicles Only) Use the following steps to create an access hole in the rear floor area of extended cab vehicles. This procedure only applies to the rear set of mounting bolts. Note This procedure below is for the left side of the vehicle. The procedure and measurements are the same for both the left and right side procedures. 1. Remove the seat located above the affected bolt. Refer to Rear Seat Replacement in SI. 2. Partially remove (pull back) the floor covering (carpet) to expose the seat mounting stud area of the floor. 3. Apply masking tape to the repair area as shown. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body Body Mount Bolt Stripped or Will Not Loosen > Page 15278 4. Using a straight edge, create a line along the inboard side of the seat mounting studs as shown. 5. Measure and mark as shown (A), 10 mm (3/8 in). 6. Find the center point between the two mounting studs as shown. Create a second mark as shown. 7. Use a center punch to create a mark in the sheet metal. 8. Using a 1-1/2 in. hole saw, create an access hole as shown. 9. Service the cab mounting bolt and nut as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body Body Mount Bolt Stripped or Will Not Loosen > Page 15279 10. Coat the perimeter of the access hole with RTV Silicone Sealant, GM P/N 12378521 (in Canada, 88901148) or equivalent, to seal the bare edge of the metal. 11. Install the round body plug, GM P/N 15908858. Ensure that the plug is sealed with the silicone sealant. 12. Reinstall the floor covering and seat. Cage Nut Access Using Rectangular Service Plug Rectangular service holes have been provided in the floor of the cab to access the cage nut in all other cab mounting bolt locations. The service hole is directly above the cab mount bolt. Use the following steps to remove and replace the service plugs that cover the service hole. 1. Remove the seat located above the affected bolt. Refer to SI for the applicable seat removal steps. 2. Remove the sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement in SI. 3. Partially remove (pull back) the floor covering (carpet) to expose the rectangular service plug. 4. Using a gasket scraper or similar tool, pry off and discard the rectangular floor plug. 5. Service the cab mounting bolt and nut as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body Body Mount Bolt Stripped or Will Not Loosen > Page 15280 6. Coat the perimeter of the access hole with RTV Silicone Sealant, GM P/N 12378521 (in Canada, 88901148) or equivalent, to seal the bare edge of the metal. 7. Install the rectangular body plug, GM P/N 15040085. Ensure that the plug is sealed with the silicone sealant. 8. Reinstall the floor covering, sill trim and seat. Parts Information Warranty Information In most cases, this bulletin information will be used when replacing a body mount and should be claimed under labor code E1095 Drivetrain and Front Suspension Frame Insulator Replacement. If this repair is performed while repairing something different, use the labor code associated with that repair. - Incremental time for this repair should be claimed using Other Labor Hours (OLH). - The recommended OLH for this repair is 0.3-0.5 hr per bolt. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 06-08-61-003F > Apr > 11 > Body/Frame - Underbody Pop/Clunk When Turning Body / Frame Mount Bushing: All Technical Service Bulletins Body/Frame - Underbody Pop/Clunk When Turning TECHNICAL Bulletin No.: 06-08-61-003F Date: April 12, 2011 Subject: Underbody Pop or Clunk Type Noise While Turning or Driving on Uneven Road Surfaces (Install Body Mount Insulator) Models: 2004-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2004-2012 Chevrolet Avalanche, Silverado (Classic), Silverado, Suburban, Tahoe 2004-2012 GMC Sierra (Classic), Sierra Denali (Classic), Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-61-003E (Section 08 - Body and Accessories). Condition Some customers may comment on a pop or clunk type noise while turning or driving on uneven road surfaces. This noise can be heard and/or felt at either the driver's or front passenger floor pan area. Cause Under certain conditions, normal movement between the frame and the #1, #2 or #3 body mounts may cause this noise to occur. Diagnosis 1. If the vehicle is equipped with aftermarket (non-GM Accessory) running boards or the running board is mounted using the body mount bolt, remove the running boards prior to test driving the vehicle. This will eliminate the running boards as the possible cause of the noise. 2. Install the J-39570 Chassis Ears to the frame rail at or near the body mounts. 3. Test drive the vehicle to identify which mount is suspect. Correction Install an insulator at the suspect mount(s). The insulator should be installed between the upper portion of the body mount and the frame bracket. The #1 mount is the mount located just under the A-pillar. The #2 mount is the mount located just under the B-pillar. The #3 mount is the mount located just under the C-pillar. Use the procedure listed below. 1. Raise the vehicle on the hoist. It is recommended to use a four-post lift or strap the vehicle frame to the hoist arms. 2. For the left side mounts only, remove the intermediate park brake cable. Perform the following steps: 1. Remove the nut from the park brake equalizer. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 3. Remove all of the body mount bolts on the side being repaired. 4. Properly support the body at the body mount area. Caution When you remove the body mount, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 06-08-61-003F > Apr > 11 > Body/Frame - Underbody Pop/Clunk When Turning > Page 15286 5. Lower the chassis accordingly in order to remove the upper portion of the body mount. 6. Install the new insulator to the bottom of the top portion of the body mount. The picture shows the insulator (1) location after the body mount is reassembled. 7. Install the body mount to the frame bracket. 8. Perform the following procedure before installing the bolts. 1. Clean the bolt threads of all the original thread locking compound. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker, GM P/N 89021297 (In Canada, use P/N 10953488). 9. Install the body mount bolts. Tighten For 2003, 2004 and 2005 model year, tighten the bolts to 85 Nm (63 lb ft). Tighten For 2006-2012 model year, tighten the bolts to 100 Nm (74 lb ft). 10. Reinstall the intermediate park brake cable (left side only). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body - Body Mount Bolt Stripped or Will Not Loosen Body / Frame Mount Bushing: All Technical Service Bulletins Body - Body Mount Bolt Stripped or Will Not Loosen INFORMATION Bulletin No.: 10-08-61-001A Date: February 16, 2011 Subject: Information on Body Mount Bolt Stripped or Will Not Loosen Models: 2010-2011 Chevrolet Silverado 2010-2011 GMC Sierra Supercede: This bulletin is being revised to add Warranty Information. Please discard Corporate Bulletin Number 10-08-61-001 (Section 08 - Body and Accessories). The purpose of this bulletin is to provide guidance to GM dealers when performing repairs that involve the removal of the body mount bolts. Technicians may discover that one of the cab mount bolts won't loosen from the vehicle. The bolt may act like the nut is cross-threaded or no longer secured to the floorpan of the vehicle. The cab mounted cage nut may have bent or broken loose allowing the nut to spin. If the nut is allowed to spin, it may prevent the bolt from loosening. The front cab mount nuts are welded to the body structure and are not involved with this bulletin. The cage nut assembly must be accessed from inside of the vehicle if this condition occurs. Some of the cage nuts have rectangular access plates in the floor of the passenger compartment. These plates are located above the affected bolt. On extended cab vehicles it is necessary to create access holes in the rear floor area to reach the rear cage nut. Creating Access Hole (Extended Cab Vehicles Only) Use the following steps to create an access hole in the rear floor area of extended cab vehicles. This procedure only applies to the rear set of mounting bolts. Note This procedure below is for the left side of the vehicle. The procedure and measurements are the same for both the left and right side procedures. 1. Remove the seat located above the affected bolt. Refer to Rear Seat Replacement in SI. 2. Partially remove (pull back) the floor covering (carpet) to expose the seat mounting stud area of the floor. 3. Apply masking tape to the repair area as shown. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body - Body Mount Bolt Stripped or Will Not Loosen > Page 15291 4. Using a straight edge, create a line along the inboard side of the seat mounting studs as shown. 5. Measure and mark as shown (A), 10 mm (3/8 in). 6. Find the center point between the two mounting studs as shown. Create a second mark as shown. 7. Use a center punch to create a mark in the sheet metal. 8. Using a 1-1/2 in. hole saw, create an access hole as shown. 9. Service the cab mounting bolt and nut as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body - Body Mount Bolt Stripped or Will Not Loosen > Page 15292 10. Coat the perimeter of the access hole with RTV Silicone Sealant, GM P/N 12378521 (in Canada, 88901148) or equivalent, to seal the bare edge of the metal. 11. Install the round body plug, GM P/N 15908858. Ensure that the plug is sealed with the silicone sealant. 12. Reinstall the floor covering and seat. Cage Nut Access Using Rectangular Service Plug Rectangular service holes have been provided in the floor of the cab to access the cage nut in all other cab mounting bolt locations. The service hole is directly above the cab mount bolt. Use the following steps to remove and replace the service plugs that cover the service hole. 1. Remove the seat located above the affected bolt. Refer to SI for the applicable seat removal steps. 2. Remove the sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement in SI. 3. Partially remove (pull back) the floor covering (carpet) to expose the rectangular service plug. 4. Using a gasket scraper or similar tool, pry off and discard the rectangular floor plug. 5. Service the cab mounting bolt and nut as required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body - Body Mount Bolt Stripped or Will Not Loosen > Page 15293 6. Coat the perimeter of the access hole with RTV Silicone Sealant, GM P/N 12378521 (in Canada, 88901148) or equivalent, to seal the bare edge of the metal. 7. Install the rectangular body plug, GM P/N 15040085. Ensure that the plug is sealed with the silicone sealant. 8. Reinstall the floor covering, sill trim and seat. Parts Information Warranty Information In most cases, this bulletin information will be used when replacing a body mount and should be claimed under labor code E1095 Drivetrain and Front Suspension Frame Insulator Replacement. If this repair is performed while repairing something different, use the labor code associated with that repair. - Incremental time for this repair should be claimed using Other Labor Hours (OLH). - The recommended OLH for this repair is 0.3-0.5 hr per bolt. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Drivetrain and Front Suspension Frame Insulator Replacement (Extended Cab) Body / Frame Mount Bushing: Service and Repair Drivetrain and Front Suspension Frame Insulator Replacement (Extended Cab) Drivetrain and Front Suspension Frame Insulator Replacement (Extended Cab) Removal Procedure Note: Ensure that the vehicle is unloaded prior to body removal. 1. Remove the master cylinder. Perform the following steps: 1. Remove the nuts retaining the master cylinder to the brake booster. 2. Remove the master cylinder from the brake booster. 3. Secure the cylinder away from the booster. 2. Raise the vehicle on the hoist. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the park brake equalizer intermediate cable. Perform the following steps: 1. Remove the nut from the park brake equalizer intermediate cable. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 4. Remove the body mount bolts. 5. Properly support the body in the area that the mounts will be replaced. Warning When you remove the body cushions, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result if you do not follow the guides outlined below: * Intermediate steering shaft-Do not allow the shaft to extend more than 25 mm (1 in). * Fuel tank filler hose-Do not stretch the hose excessively. * Tail/Turn signal lamp wiring/rear lamps junction block-Leave slack in the wires. * Park brake cable-Leave slack in the cable. * Body ground straps-Leave slack in the wire. 6. Lower the chassis accordingly in order to remove the cushions (1) as necessary. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Drivetrain and Front Suspension Frame Insulator Replacement (Extended Cab) > Page 15296 1. Install the cushions (1) as necessary and raise the chassis accordingly. 2. Perform the following procedure before installing the bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the body mount bolts and tighten to 60 Nm (44 lb ft) plus 170 degrees. 4. Install the park brake equalizer intermediate cable. Perform the following steps: 1. Pull rearward on the park brake cable to the original position. 2. Secure the cable retaining tabs to the frame. 3. Install the intermediate cable end to the equalizer. 4. Install the nut to the threaded end of the intermediate cable. Tighten the nut to 4 Nm (35 lb in). 5. Lower the vehicle. 6. Install the master cylinder. Perform the following steps: 1. Mount the master cylinder to the brake booster. 2. Install the master cylinder mounting nuts and tighten to 36 Nm (27 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Drivetrain and Front Suspension Frame Insulator Replacement (Extended Cab) > Page 15297 Body / Frame Mount Bushing: Service and Repair Drivetrain and Front Suspension Frame Insulator Replacement (Regular Cab) Drivetrain and Front Suspension Frame Insulator Replacement (Regular Cab) Removal Procedure Note: Ensure that the vehicle is unloaded prior to body removal. 1. Remove the master cylinder. Perform the following steps: 1. Remove the nuts retaining the master cylinder to the brake booster. 2. Remove the master cylinder from the brake booster. 3. Secure the cylinder away from the booster. 2. Raise the vehicle on the hoist. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the park brake equalizer intermediate cable. Perform the following steps: 1. Remove the nut from the park brake equalizer intermediate cable. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 4. Remove the body mount bolts. 5. Properly support the body in the area that the mounts will be replaced. Warning When you remove the body cushions, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result if you do not follow the guides outlined below: * Intermediate steering shaft-Do not allow the shaft to extend more than 25 mm (1 in). * Fuel tank filler hose-Do not stretch the hose excessively. * Tail/Turn signal lamp wiring/rear lamps junction block-Leave slack in the wires. * Park brake cable-Leave slack in the cable. * Body ground straps-Leave slack in the wire. 6. Lower the chassis accordingly in order to remove the cushions (1) as necessary. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Drivetrain and Front Suspension Frame Insulator Replacement (Extended Cab) > Page 15298 1. Install the cushions (1) as necessary and raise the chassis accordingly. 2. Perform the following procedure before installing the bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the body mount bolts and tighten to 60 Nm (44 lb ft) plus 170 degrees. 4. Install the park brake equalizer intermediate cable. Perform the following steps: 1. Pull rearward on the park brake cable to the original position. 2. Secure the cable retaining tabs to the frame. 3. Install the intermediate cable end to the equalizer. 4. Install the nut to the threaded end of the intermediate cable. Tighten the nut to 4 Nm (35 lb in). 5. Lower the vehicle. 6. Install the master cylinder. Perform the following steps: 1. Mount the master cylinder to the brake booster. 2. Install the master cylinder mounting nuts and tighten to 36 Nm (27 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair Cross-Member: Service and Repair Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500, 2500 LD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) Skid Plate: Service and Repair Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the mounting bolts for the oil pan skid plate. 3. Remove the oil pan skid plate. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the mounting bolts for the oil pan skid plate. 6. Remove the oil pan skid plate. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) > Page 15306 1. Position the oil skid plate on the frame. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the oil skid plate mounting bolts and tighten to 28 Nm (21 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) > Page 15307 Skid Plate: Service and Repair Engine Shield Replacement Engine Shield Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Structural Brace > Component Information > Service and Repair Structural Brace: Service and Repair Front End Sheet Metal Diagonal Brace Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) Trailer Hitch: Service and Repair Trailer Hitch Replacement (Light Duty) Trailer Hitch Replacement (Light Duty) Removal Procedure 1. Disconnect the trailer wiring harness connector (3) from the trailer wiring receptacle (4). 2. Remove the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 3. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 4. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 5. Remove the hitch platform bolts (6) from the frame weld nuts (2). 6. Remove the hitch platform from the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 15315 1. Position the hitch platform to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 Nm (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 Nm (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 Nm (74 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 15316 5. Install the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 6. Connect the trailer wiring harness connector (3) to the trailer wiring receptacle (4). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 15317 Trailer Hitch: Service and Repair Trailer Hitch Replacement (Heavy Duty) Trailer Hitch Replacement (Heavy Duty) Removal Procedure 1. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 2. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 3. Remove the hitch platform bolts (6) from the frame weld nuts (2). 4. Remove the hitch platform from the vehicle. Installation Procedure 1. Position the hitch platform to the vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 15318 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 Nm (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 Nm (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 Nm (74 lb ft). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Diagrams Trailer Towing Relay: Diagrams Component Connector End Views Trailer Brake Control Relay (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Diagrams > Page 15322 Trailer Towing Relay: Service and Repair Trailer Brake Control Relay Replacement (1500) Removal Procedure 1. Turn the ignition switch to the OFF position. Note: Do not remove the spare tire and wheel hoist. 2. Remove the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair). 3. Disconnect the trailer brake control relay electrical connector. Note: It is not necessary to completely remove the bolts. 4. Loosen, but do not remove, the trailer brake control relay bolts (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Diagrams > Page 15323 5. Slide the trailer brake control relay (1) toward the center of the vehicle and remove the trailer brake control relay. Installation Procedure 1. If installing a new trailer brake control relay, hand start the 2 trailer brake control relay bolts. 2. Position the trailer brake control relay to the frame bracket. 3. Slide the trailer brake control relay (1) toward the left frame rail. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Diagrams > Page 15324 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the trailer brake control relay bolts (1) to 6 Nm (53 lb in). 5. Connect the trailer brake control relay electrical connector. 6. Install the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille Replacement Grille: Service and Repair Radiator Grille Replacement Radiator Grille Replacement (Chevrolet) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille Replacement > Page 15329 Grille: Service and Repair Radiator Grille Replacement (Chevrolet HD) Radiator Grille Replacement (Chevrolet HD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille Replacement > Page 15330 Grille: Service and Repair Radiator Grille Replacement (GMC HD) Radiator Grille Replacement (GMC HD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair Ash Tray: Service and Repair Ashtray Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle Carpet: Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15339 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15340 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15341 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15342 Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15343 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures Carpet: Procedures Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, GM P/N 88861431 (Canadian P/N 88861436), may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. * Instructions and cautions are printed on the bottle, but additional help is available. Drying Floor Carpet Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. * For a 1-piece carpet assembly with a separate cotton or a fiber padding, replace the cotton or fiber padding. While the carpet is out of the vehicle, dry the carpet using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 15346 Carpet: Removal and Replacement Front Floor Panel Carpet Replacement (Regular Cab) Front Floor Panel Carpet Replacement (Regular Cab) Front Floor Panel Carpet Replacement (Extended Cab) Front Floor Panel Carpet Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 15347 Front Floor Panel Carpet Replacement (Crew Cab) Front Floor Panel Carpet Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 15348 Body Rear Inner Panel Carpet Replacement (Regular Cab) Body Rear Inner Panel Carpet Replacement (Regular Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 15349 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement Console: Service and Repair Front Floor Console Compartment Bezel Replacement Front Floor Console Compartment Bezel Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15354 Console: Service and Repair Front Floor Console Compartment Door Latch Replacement (Except Cadillac) Front Floor Console Compartment Door Latch Replacement (Except Cadillac) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15355 Console: Service and Repair Front Floor Console Side Trim Panel Replacement - Right Side (with RPO SLT) Front Floor Console Side Trim Panel Replacement - Right Side (with RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15356 Console: Service and Repair Front Floor Console Side Trim Panel Replacement - Left Side (with RPO SLT) Front Floor Console Side Trim Panel Replacement - Left Side (with RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15357 Console: Service and Repair Front Floor Console Compartment Bezel Replacement Front Floor Console Compartment Bezel Replacement Front Floor Console Compartment Door Latch Replacement (Except Cadillac) Front Floor Console Compartment Door Latch Replacement (Except Cadillac) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15358 Front Floor Console Side Trim Panel Replacement - Right Side (with RPO SLT) Front Floor Console Side Trim Panel Replacement - Right Side (with RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15359 Front Floor Console Side Trim Panel Replacement - Left Side (with RPO SLT) Front Floor Console Side Trim Panel Replacement - Left Side (with RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15360 Floor Console Bezel Replacement Floor Console Bezel Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15361 Front Floor Console Compartment Replacement (Except Cadillac) Front Floor Console Compartment Replacement (Except Cadillac) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15362 Front Floor Console Replacement (without RPO SLT) Front Floor Console Replacement (without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15363 Front Floor Console Replacement (with RPO SLT) Front Floor Console Replacement (with RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15364 Front Floor Console Armrest Replacement Front Floor Console Armrest Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15365 Center Console End Panel Replacement Center Console End Panel Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15366 Roof Console Replacement Roof Console Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15367 Roof Rear Console Replacement (with DVD) Roof Rear Console Replacement (with DVD) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15368 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 15373 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair Drink Holders: Service and Repair Front Floor Console Cup Holder Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement Glove Compartment: Service and Repair Instrument Panel Storage Compartment Replacement Instrument Panel Storage Compartment Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15381 Glove Compartment: Service and Repair Instrument Panel Compartment Door Lock Striker Replacement (With RPO SLT) Instrument Panel Compartment Door Lock Striker Replacement (With RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15382 Glove Compartment: Service and Repair Instrument Panel Compartment Door Emblem Replacement (TUF) Instrument Panel Compartment Door Emblem Replacement (TUF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15383 Glove Compartment: Service and Repair Instrument Panel Compartment Door Replacement (With RPO SLT) Instrument Panel Compartment Door Replacement (With RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15384 Glove Compartment: Service and Repair Instrument Panel Storage Compartment Replacement Instrument Panel Storage Compartment Replacement Instrument Panel Compartment Door Lock Striker Replacement (With RPO SLT) Instrument Panel Compartment Door Lock Striker Replacement (With RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15385 Instrument Panel Compartment Door Emblem Replacement (TUF) Instrument Panel Compartment Door Emblem Replacement (TUF) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15386 Instrument Panel Compartment Door Replacement (With RPO SLT) Instrument Panel Compartment Door Replacement (With RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15387 Instrument Panel Compartment Door Assembly Replacement (With RPO SLT) Instrument Panel Compartment Door Assembly Replacement (With RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15388 Instrument Panel Compartment Door Opening Frame Replacement (without RPO SLT) Instrument Panel Compartment Door Opening Frame Replacement (without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15389 Instrument Panel Compartment Door Latch Replacement (With RPO SLT) Instrument Panel Compartment Door Latch Replacement (With RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15390 Instrument Panel Compartment Door Latch Replacement (Without RPO SLT) Instrument Panel Compartment Door Latch Replacement (Without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15391 Instrument Panel Compartment Door Lock Cylinder Replacement Instrument Panel Compartment Door Lock Cylinder Replacement Removal Procedure 1. Remove the instrument panel compartment latch. Refer to Instrument Panel Compartment Door Latch Replacement (With RPO SLT) (See: Instrument Panel Compartment Door Latch Replacement (With RPO SLT))Instrument Panel Compartment Door Latch Replacement (Without RPO SLT) (See: Instrument Panel Compartment Door Latch Replacement (Without RPO SLT)). 2. Position the instrument panel compartment latch fork bolt in the up position. 3. Insert the key into the instrument panel compartment lock cylinder. 4. Rotate the instrument panel compartment lock cylinder clockwise to the 3 o'clock position with the key. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15392 5. With the key in position, apply a light load and depress the retainer tumbler through the poke hole at the right hand side of the instrument panel compartment latch. 6. Rotate the key until the instrument panel compartment lock cylinder rotates to about the 5 o'clock position. This will line up the notch at the rear of the instrument panel compartment lock cylinder with the tab in the instrument panel compartment latch housing. 7. Remove the instrument panel compartment lock cylinder from the instrument panel compartment latch by pulling on the key. Installation Procedure 1. Position the instrument panel compartment latch fork bolt in the up position. 2. Grasp the instrument panel compartment lock cylinder. Depress the rear-most, light-colored tumbler that is flush with the instrument panel compartment lock cylinder surface. 3. Insert the key. All the tumblers will now stay depressed. 4. Insert the instrument panel compartment lock cylinder, with the key inserted, into the instrument panel compartment latch housing. Ensure that the front projection pin is at the appropriate 8 o'clock position. The instrument panel compartment lock cylinder will drop into place. 5. Rotate the key counterclockwise until the key stops. 6. Remove the key, the tumblers will now release. The instrument panel compartment lock cylinder is now locked into the instrument panel compartment latch housing. 7. Install the instrument panel compartment latch. Refer to Instrument Panel Compartment Door Latch Replacement (With RPO SLT) (See: Instrument Panel Compartment Door Latch Replacement (With RPO SLT))Instrument Panel Compartment Door Latch Replacement (Without RPO SLT) (See: Instrument Panel Compartment Door Latch Replacement (Without RPO SLT)). Instrument Panel Compartment Door Dampener Replacement (With RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15393 Instrument Panel Compartment Door Dampener Replacement (With RPO SLT) Instrument Panel Compartment Door Dampener Replacement (Without RPO SLT) Instrument Panel Compartment Door Dampener Replacement (Without RPO SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15394 Instrument Panel Upper Compartment Replacement Instrument Panel Upper Compartment Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15395 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Regular Cab) Headliner: Service and Repair Headlining Trim Panel Replacement (Regular Cab) Headlining Trim Panel Replacement (Regular Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Regular Cab) > Page 15400 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Regular Cab) > Page 15401 Headliner: Service and Repair Headlining Trim Panel Replacement (Extended Cab) Headlining Trim Panel Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Regular Cab) > Page 15402 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Regular Cab) > Page 15403 Headliner: Service and Repair Headlining Trim Panel Replacement (Crew Cab) Headlining Trim Panel Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Regular Cab) > Page 15404 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Front Assist Handle Replacement Passenger Assist Handle: Service and Repair Front Assist Handle Replacement Front Assist Handle Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Front Assist Handle Replacement > Page 15409 Passenger Assist Handle: Service and Repair Center Pillar Assist Handle Replacement Center Pillar Assist Handle Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Front Assist Handle Replacement > Page 15410 Passenger Assist Handle: Service and Repair Roof Rail Rear Assist Handle Replacement Roof Rail Rear Assist Handle Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Front Side Door Sill Trim Plate Replacement (Extended Cab) Scuff Plate: Service and Repair Front Side Door Sill Trim Plate Replacement (Extended Cab) Front Side Door Sill Trim Plate Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Front Side Door Sill Trim Plate Replacement (Extended Cab) > Page 15415 Scuff Plate: Service and Repair Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Front Side Door Sill Trim Plate Replacement (Extended Cab) > Page 15416 Scuff Plate: Service and Repair Rear Side Door Sill Trim Plate Replacement (Crew Cab) Rear Side Door Sill Trim Plate Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Front Side Door Sill Trim Plate Replacement (Extended Cab) > Page 15417 Scuff Plate: Service and Repair Rear Side Door Sill Trim Plate Replacement (Extended Cab) Rear Side Door Sill Trim Plate Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest for Sun Visor: > 09-08-110-013A > Apr > 11 > Interior - Sun Visor Fails to Stay In Up Position Sun Visor: Customer Interest Interior - Sun Visor Fails to Stay In Up Position TECHNICAL Bulletin No.: 09-08-110-013A Date: April 18, 2011 Subject: Sunshade (Sun Visor) Fails to Stay In Position (Re-seat Detent Spring) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to include the 2012 model year. Please discard Corporate Bulletin Number 09-08-110-013 (Section 08 - Body and Accessories). Condition Some customers may comment that the front sunshade (sun visor) doesn't stay in position tightly against the headliner when in the up position and clipped into the center mount. Cause The condition may be caused by the sunshade being over extended (forced) along the slide on rod to the end of its travel. This over extension can cause the detent spring to be pulled off of the flat on the slide on rod and can cause the detent function to be inoperative. Correction In many cases, the detent spring can be re-seated into the correct position. Use the following procedure to correct the condition. 1. Position the sunshade in the forward position and engage the sunshade into the center clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest for Sun Visor: > 09-08-110-013A > Apr > 11 > Interior - Sun Visor Fails to Stay In Up Position > Page 15426 2. Cycle the sunshade up and down 15-20 cycles. This should engage the detent spring. 3. Repeat the procedure on the second visor. If the above steps fail to resolve the condition, refer to diagnostic procedures in SI to correct the condition. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Visor: > 09-08-110-013A > Apr > 11 > Interior - Sun Visor Fails to Stay In Up Position Sun Visor: All Technical Service Bulletins Interior - Sun Visor Fails to Stay In Up Position TECHNICAL Bulletin No.: 09-08-110-013A Date: April 18, 2011 Subject: Sunshade (Sun Visor) Fails to Stay In Position (Re-seat Detent Spring) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to include the 2012 model year. Please discard Corporate Bulletin Number 09-08-110-013 (Section 08 - Body and Accessories). Condition Some customers may comment that the front sunshade (sun visor) doesn't stay in position tightly against the headliner when in the up position and clipped into the center mount. Cause The condition may be caused by the sunshade being over extended (forced) along the slide on rod to the end of its travel. This over extension can cause the detent spring to be pulled off of the flat on the slide on rod and can cause the detent function to be inoperative. Correction In many cases, the detent spring can be re-seated into the correct position. Use the following procedure to correct the condition. 1. Position the sunshade in the forward position and engage the sunshade into the center clip. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Visor: > 09-08-110-013A > Apr > 11 > Interior - Sun Visor Fails to Stay In Up Position > Page 15432 2. Cycle the sunshade up and down 15-20 cycles. This should engage the detent spring. 3. Repeat the procedure on the second visor. If the above steps fail to resolve the condition, refer to diagnostic procedures in SI to correct the condition. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sunshade Sun Visor: Service and Repair Sunshade Sunshade Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sunshade > Page 15435 Sun Visor: Service and Repair Sunshade Anchor Replacement Sunshade Anchor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement Trim Panel: Service and Repair Body Hinge Pillar Trim Panel Replacement Body Hinge Pillar Trim Panel Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15440 Trim Panel: Service and Repair Body Lock Pillar Trim Replacement (Crew Cab) Body Lock Pillar Trim Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15441 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15442 Trim Panel: Service and Repair Body Lock Pillar Trim Replacement (Extended Cab) Body Lock Pillar Trim Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15443 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15444 Trim Panel: Service and Repair Body Lock Pillar Trim Replacement (Regular Cab) Body Lock Pillar Trim Replacement (Regular Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15445 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15446 Trim Panel: Service and Repair Body Hinge Pillar Trim Panel Replacement Body Hinge Pillar Trim Panel Replacement Body Lock Pillar Trim Replacement (Crew Cab) Body Lock Pillar Trim Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15447 Body Lock Pillar Trim Replacement (Extended Cab) Body Lock Pillar Trim Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15448 Body Lock Pillar Trim Replacement (Regular Cab) Body Lock Pillar Trim Replacement (Regular Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15449 Center Pillar Lower Garnish Molding Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15450 Center Pillar Lower Garnish Molding Replacement Center Pillar Upper Garnish Molding Replacement Center Pillar Upper Garnish Molding Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15451 Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15452 Jack Stowage Cover Replacement Jack Stowage Cover Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15453 Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15454 Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15455 Rear Window Lower Garnish Molding Replacement (Regular Cab) Rear Window Lower Garnish Molding Replacement (Regular Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15456 Windshield Pillar Garnish Molding Replacement Windshield Pillar Garnish Molding Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15457 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Door Lock Cylinder Replacement Door Lock Cylinder: Service and Repair Door Lock Cylinder Replacement Door Lock Cylinder Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Door Lock Cylinder Replacement > Page 15464 Door Lock Cylinder: Service and Repair Endgate Lock Cylinder Replacement Endgate Lock Cylinder Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 15469 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 15470 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 15471 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Antenna - Keyless Entry > Component Information > Service and Repair > Keyless Entry Antenna Replacement (Regular Cab) Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Regular Cab) Keyless Entry Antenna Replacement (Regular Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Antenna - Keyless Entry > Component Information > Service and Repair > Keyless Entry Antenna Replacement (Regular Cab) > Page 15477 Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Extended/Crew Cab) Keyless Entry Antenna Replacement (Extended/Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams Keyless Entry Receiver: Diagrams Component Connector End Views Remote Control Door Lock Receiver (RCDLR) (AP3 or AP8) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter Diagnostic Tip INFORMATION Bulletin No.: 09-08-52-004A Date: January 08, 2010 Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter When Transmitter Battery is Weak or Dead Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR, Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories). Follow these procedures if a customer comments that their GM Accessory 2-way transmitter stopped communicating with the vehicle. About GM Accessory 2-Way Remote Start The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a 2-way advanced remote start system, but often the 2-way transmitter may only be coded to one vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter will enter second vehicle mode and will not control the original vehicle until a subsequent double press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of the 2-way transmitter should be thought of as an individual transmitter with its own unique code. Test the Transmitter Battery Note This test should be performed prior to releasing the vehicle or transmitter to the customer. All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or replacement of a transmitter battery using the following procedure. 1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of the unlock button, observe the battery gauge located in the upper right corner of the LCD display. The gauge should read full (three bars inside the battery icon). If after having a new battery installed, the battery goes dead within five months, the transmitter could have high sleep current, causing the battery to go dead. Replace the transmitter. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. Determine if Transmitter is in Second Vehicle Mode 1. Press and release any of the face buttons on the 2-way transmitter and observe the display on power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be displayed on the left side of the transmitter display. Is the 2-way transmitter in second vehicle mode? If Yes, the 2-way transmitter is working properly. - Press and release the left side button twice within one second. The 2-way transmitter should exit second vehicle mode. - Press and release the lock button. Press and release the unlock button. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 15489 - Confirm that the vehicle responds with the appropriate lock and unlock function. - If Yes , the 2-way transmitter was in mode B. - Press and release the left side button twice within one second. The 2-way transmitter should enter second vehicle mode. - Use the "next available slot" method in the scan tool to program the 2-way transmitter to the 2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI. - Both vehicle modes of the 2-way transmitter should now be coded to the vehicle. If No: The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal diagnostic procedures. Parts Information For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts Catalog or Corporate Bulletin Number 09-00-89-025A. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 15490 Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote Start INFORMATION Bulletin No.: 09-00-89-025A Date: October 26, 2009 Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT 2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent 2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA, OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY Attention: This bulletin does not apply to GMODC dealers. Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin Number 09-00-89-025 (Section 00 - General Information). This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems. Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 15491 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 15492 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 15493 Parts Information Service parts common to all 2-Way Advanced Remote Start Systems Transmitter Battery 12493150 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-52-001G > Aug > 10 > Keyless Entry Intermittent/Inoperative Remote Keyless Entry Transmitter: Customer Interest Keyless Entry - Intermittent/Inoperative Remote TECHNICAL Bulletin No.: 08-08-52-001G Date: August 24, 2010 Subject: EI08028 - Intermittent, Inoperative Remote Keyless Entry (RKE) (Reprogram Key Fobs) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to change the labor operation number. Please discard Corporate Bulletin Number 08-08-52-001F (Section 08 - Body and Accessories). Condition Some customers may comment that one or more key fobs are inoperative. A number of warranty claims have been submitted that show relearning the key fobs has corrected this concern. Cause Based on technician feedback, engineering has determined two possible causes for key fob concerns: - The fobs may not be programmed when the vehicles leave the plant. - There may be Issues with the fobs internal components. Correction To correct the customer's concern, reprogram the transmitter (key fob). Refer to the procedure for Transmitter Programming found in Service Information. If reprogramming the transmitter is not successful, it will be necessary to replace the transmitter. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-08-52-001G > Aug > 10 > Keyless Entry - Intermittent/Inoperative Remote Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Intermittent/Inoperative Remote TECHNICAL Bulletin No.: 08-08-52-001G Date: August 24, 2010 Subject: EI08028 - Intermittent, Inoperative Remote Keyless Entry (RKE) (Reprogram Key Fobs) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to change the labor operation number. Please discard Corporate Bulletin Number 08-08-52-001F (Section 08 - Body and Accessories). Condition Some customers may comment that one or more key fobs are inoperative. A number of warranty claims have been submitted that show relearning the key fobs has corrected this concern. Cause Based on technician feedback, engineering has determined two possible causes for key fob concerns: - The fobs may not be programmed when the vehicles leave the plant. - There may be Issues with the fobs internal components. Correction To correct the customer's concern, reprogram the transmitter (key fob). Refer to the procedure for Transmitter Programming found in Service Information. If reprogramming the transmitter is not successful, it will be necessary to replace the transmitter. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 10-08-52-003 > Jul > 10 > Keyless Entry - Transmitter Button Inop/Won't Program Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter Button Inop/Won't Program INFORMATION Bulletin No.: 10-08-52-003 Date: July 21, 2010 Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to Vehicle Models: 2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007 Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade, Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express 2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry Attention: This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry (RKE) transmitter operation. This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may be inoperative intermittently or in which a particular button(s) does not work. To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are depressed longer than 30 seconds. The disabled button or buttons will remain disabled until another button that has not been disabled is pressed. If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed to a vehicle, press and release each and every button on the fob one at a time until you find one that works then retest the other buttons. If all buttons are now working, the button(s) were disabled and the transmitter is working as designed. If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics as shown in SI. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 10-08-52-003 > Jul > 10 > Keyless Entry - Transmitter Button Inop/Won't Program Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter Button Inop/Won't Program INFORMATION Bulletin No.: 10-08-52-003 Date: July 21, 2010 Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to Vehicle Models: 2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007 Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade, Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express 2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry Attention: This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry (RKE) transmitter operation. This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may be inoperative intermittently or in which a particular button(s) does not work. To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are depressed longer than 30 seconds. The disabled button or buttons will remain disabled until another button that has not been disabled is pressed. If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed to a vehicle, press and release each and every button on the fob one at a time until you find one that works then retest the other buttons. If all buttons are now working, the button(s) were disabled and the transmitter is working as designed. If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics as shown in SI. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Transmitter: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15518 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15519 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15520 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15521 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15522 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15523 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15524 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15525 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15526 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15527 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15528 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15529 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15530 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15531 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15532 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15533 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15534 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15535 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15536 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15537 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15538 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15539 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15540 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15541 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15542 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15543 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15544 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15545 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15546 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15547 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15548 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15549 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15550 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15551 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15552 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15553 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15554 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15555 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15556 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15557 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15558 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15559 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15560 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15561 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15562 Keyless Entry Transmitter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15563 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15564 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15565 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15566 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15567 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15568 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15569 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15570 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15571 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15572 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15573 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15574 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15575 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15576 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15577 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15578 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15579 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15580 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15581 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15582 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15583 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15584 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15585 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15586 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15587 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15588 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15589 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15590 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15591 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15592 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15593 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15594 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15595 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15596 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15597 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15598 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15599 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15600 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15601 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15602 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15603 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15604 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15605 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15606 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15607 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15608 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15609 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15610 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15611 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15612 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15613 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15614 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15615 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15616 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15617 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15618 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15619 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15620 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15621 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15622 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15623 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15624 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15625 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15626 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15627 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15628 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15629 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15630 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15631 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15632 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15633 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15634 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15635 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15636 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15637 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15638 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15639 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15640 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15641 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15642 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15643 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15644 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15645 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15646 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15647 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15648 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15649 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15650 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15651 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15652 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15653 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15654 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15655 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15656 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15657 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15658 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15659 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15660 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15661 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15662 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15663 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15664 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15665 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15666 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15667 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15668 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15669 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15670 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15671 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15672 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15673 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15674 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15675 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15676 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15677 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15678 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15679 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15680 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15681 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15682 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15683 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15684 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15685 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15686 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15687 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15688 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15689 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15690 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15691 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15692 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15693 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15694 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15695 Keyless Entry Transmitter: Electrical Diagrams Remote Function Schematics Keyless Entry Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Page 15696 Keyless Entry Transmitter: Tools and Equipment Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P Power Door Lock Relay: Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15702 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15703 Power Door Lock Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15704 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15705 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15706 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15707 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15708 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15709 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15710 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3 or DL3) Door Lock Switch - Passenger (AU3 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15714 Door Lock/Window Switch - Driver X1 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15715 Door Lock/Window Switch - Driver X2 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15716 Door Lock/Window Switch - Driver X3 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15717 Door Lock/Window Switch - Driver X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15718 Door Lock/Window Switch - Driver X7 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15719 Door Lock/Window Switch - Passenger X1 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15720 Door Lock/Window Switch - Passenger X2 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15721 Door Lock/Window Switch - Passenger X3 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15722 Door Lock/Window Switch - Passenger X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15723 Door Lock/Window Switch - Passenger X7 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15724 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Front (with DL8 and without SLT) Door Lock Switch Replacement - Front (with DL8 and without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) > Page 15727 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) > Page 15728 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Binding In many cases, applying the proper lubrication can correct the following conditions: * Binding or sticking door lock cylinders * Difficulty in inserting and removing the keys For lubricating the above components, use lubricant GM P/N 12346241 or equivalent. Do not use penetrating lubricants such as GM P/N 1052949 or WD-40(R). Penetrating lubricants wash out the original lubrication. Penetrating lubricants eventually evaporate, leaving little or no lubricating material. However, when using penetrating lubricants in order to thaw or in order to loosen the lock cylinder components, refer to steps 2-4 in the procedure below for the proper methods of lubrication. Repair lock cylinders frozen in cold weather by using the following procedure: 1. While carefully avoiding damage to the painted surfaces, apply heat to the cylinder with a heat gun. 2. Using a paper clip or a similar item, hold the door shutter open. Force air into the cylinders using compressed air through a blow gun attachment. 3. While holding the shutter door open, inject small amounts of a recommended lubricant into the cylinder. 4. Work the key into the cylinder repeatedly. Wipe away any excess lubrication from the key. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Memory Positioning Module: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15741 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15742 Memory Positioning Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15743 Memory Seat Module (MSM) X3 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15744 Memory Seat Module (MSM) X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15745 Memory Seat Module (MSM) X5 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15746 Memory Seat Module (MSM) X6 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15747 Memory Seat Module (MSM) X7 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15748 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15749 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Seat Memory Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 15753 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 15754 Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair Power Mirror Motor: Service and Repair Outside Rearview Mirror Motor Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: Customer Interest Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 15766 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 15772 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Component Connector End Views Outside Rearview Mirror Switch (DL8 or DPN) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 15776 Power Mirror Switch: Service and Repair Power Mirror Switch Replacement (with DL8 and without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 15786 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 10-08-51-001 > Jan > 10 > Body/Paint - 2010 Exterior Paint Codes Paint: All Technical Service Bulletins Body/Paint - 2010 Exterior Paint Codes INFORMATION Bulletin No.: 10-08-51-001 Date: January 05, 2010 Subject: Exterior Paint Codes Models: 2010 Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 10-08-51-001 > Jan > 10 > Body/Paint - 2010 Exterior Paint Codes > Page 15792 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 10-08-51-001 > Jan > 10 > Body/Paint - 2010 Exterior Paint Codes > Page 15793 The primary exterior body paint codes on the SPID label may be missing on some 2010 vehicles. Above is a chart with the primary exterior body colors for your reference. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 15798 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 15804 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 15805 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 15806 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 15807 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 15808 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 15809 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 15810 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 15811 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Brake Fluid Effects on Paint and Electrical Components Caution Paint: Service Precautions Brake Fluid Effects on Paint and Electrical Components Caution Brake Fluid Effects on Paint and Electrical Components Caution Caution: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Brake Fluid Effects on Paint and Electrical Components Caution > Page 15814 Paint: Service Precautions Clearcoat/Ultraviolet Screeners Caution Clearcoat/Ultraviolet Screeners Caution Caution: Removing more than 0.5 mils of the clearcoat can result in early paint failure. The clearcoat contains ultraviolet screeners. Do not finesse sand more than what is required to remove the defect. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Basecoat/Clearcoat Paint Systems Paint: Application and ID Basecoat/Clearcoat Paint Systems Basecoat/Clearcoat Paint Systems Warning Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. All paint finish repairs of rigid exterior surfaces must meet GM standards. Refer to the latest revision of the GM Approved Refinish Materials book to identify the paint systems you may use that have been engineered to meet GM standards. The GM Approved Refinish Materials book supplies all approved products, including volatile organic compound (VOC) compliant regulations recommended by the individual manufacturer, and detailed procedures for materials used in their paint system. The latest revision of the GM Approved Refinish Materials booklet is located on the Goodwrench website at www.gmgoodwrench.com. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Basecoat/Clearcoat Paint Systems > Page 15817 Paint: Application and ID Paint Identification Paint Identification Warning Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Note: Always refer to the GM Approved Refinish Materials book. This book identifies the paint systems you may use. The latest revision of the GM Approved Refinish Materials booklet is located on the Goodwrench website at www.gmgoodwrench.com. Use the service parts identification label to identify the type of paint technology, paint codes, trim level, and any special order paint colors on the vehicle. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Front End Upper Tie Bar Replacement Radiator Support: Service and Repair Front End Upper Tie Bar Replacement Front End Upper Tie Bar Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Front End Upper Tie Bar Replacement > Page 15822 Radiator Support: Service and Repair Radiator Support Replacement Radiator Support Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Front End Upper Tie Bar Replacement > Page 15823 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations Memory Positioning Module: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 15831 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 15832 Memory Positioning Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 15833 Memory Seat Module (MSM) X3 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 15834 Memory Seat Module (MSM) X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 15835 Memory Seat Module (MSM) X5 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 15836 Memory Seat Module (MSM) X6 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 15837 Memory Seat Module (MSM) X7 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 15838 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 15839 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P Power Door Lock Relay: Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15844 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15845 Power Door Lock Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15846 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15847 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15848 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15849 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15850 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15851 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15852 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 15861 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 15862 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 15863 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 15864 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 15870 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 15871 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 15872 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 15873 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15874 Seat Heater Control Module: Diagrams Component Connector End Views Seat Back Ventilation Heating and Cooling Module - Driver (KB6) Seat Back Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15875 Seat Climate Control Module X1 (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15876 Seat Climate Control Module X2 (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15877 Seat Climate Control Module X3 (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15878 Seat Cushion Ventilation Heating and Cooling Module - Driver (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15879 Seat Cushion Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15880 Heated Seat Control Module X1 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15881 Heated Seat Control Module X2 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15882 Heated Seat Control Module X3 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15883 Heated Seat Control Module X4 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 15884 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Front Seat Heater Control Module Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Front Seat Heater Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Front Seat Heater Control Module > Page 15887 Seat Heater Control Module: Service and Repair Module Replacement - Seat Climate Control Front Seat (Denali with KB6) Module Replacement - Seat Climate Control - Front Seat (Denali with KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof / Moonroof Module: Diagrams Component Connector End Views Sunroof Control Module (CF5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams Trailer Towing Relay: Diagrams Component Connector End Views Trailer Brake Control Relay (JL1) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Page 15894 Trailer Towing Relay: Service and Repair Trailer Brake Control Relay Replacement (1500) Removal Procedure 1. Turn the ignition switch to the OFF position. Note: Do not remove the spare tire and wheel hoist. 2. Remove the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair). 3. Disconnect the trailer brake control relay electrical connector. Note: It is not necessary to completely remove the bolts. 4. Loosen, but do not remove, the trailer brake control relay bolts (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Page 15895 5. Slide the trailer brake control relay (1) toward the center of the vehicle and remove the trailer brake control relay. Installation Procedure 1. If installing a new trailer brake control relay, hand start the 2 trailer brake control relay bolts. 2. Position the trailer brake control relay to the frame bracket. 3. Slide the trailer brake control relay (1) toward the left frame rail. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Page 15896 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the trailer brake control relay bolts (1) to 6 Nm (53 lb in). 5. Connect the trailer brake control relay electrical connector. 6. Install the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Specifications Luggage Rack: Specifications Fastener Tightening Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Luggage Carrier Replacement Luggage Rack: Service and Repair Luggage Carrier Replacement Luggage Carrier Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Luggage Carrier Replacement > Page 15903 Luggage Rack: Service and Repair Luggage Carrier Nut Replacement Luggage Carrier Nut Replacement Removal Procedure 1. Remove the luggage carrier. Refer to Luggage Carrier Replacement (See: Luggage Carrier Replacement). Warning: Refer to Safety Glasses Warning (See: Service Precautions/Technician Safety Information/Safety Glasses Warning). 2. Drill through the luggage carrier rivnut head using a 7.5 mm (0.295 in) drill bit. 3. Remove the rivnut from the roof. Installation Procedure 1. Using a 10 mm (0.3937 in) drill bit, drill the rivnut hex shape hole in the roof out to a round 10 mm hole. 2. Install a replacement rivnut to the hole in roof using a rivnut tool, or equivalent. 3. Install the luggage carrier. Refer to Luggage Carrier Replacement (See: Luggage Carrier Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Diagrams Sun Shade: Diagrams Component Connector End Views Sunshade - Left (DH6) Sunshade - Right (DH6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Diagrams > Page 15908 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement Sun Shade: Service and Repair Sunroof Sunshade Guide Replacement Sunroof Sunshade Guide Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 15911 Sun Shade: Service and Repair Sunroof Sunshade Replacement (Extended Cab) Sunroof Sunshade Replacement (Extended Cab) Removal Procedure Important: If the sunshade spring releases, it will be necessary to rewind it. Turn the sunshade roller end slot 20 times in the counterclockwise direction. Important: A new sunshade service part comes pre-loaded with a pin tool holding spring tension on the sunshade. If the sunshade spring releases, it will be necessary to rewind it and reinstall the pin tool. Following installation, retain the pin tool for future applications. 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 2. Power the sunroof window guides to the fully open position. Important: The cam locking hole will come in to view when the sunshade is in the fully open position on the passengers side. 3. Close the sunshade (1) until the cam locking hole (2) come in to view. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 15912 4. Insert a suitable tool (1) into the sunshade cam locking hole (2). 5. Turn the sunshade (1) counterclockwise until the shade cam (2) is align with the bracket (3) notch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 15913 6. Lift upward on the sunshade (1) removing it from the bracket (2). Important: The sunshade must be removed from the top of the vehicle. 7. Push the sunshade (1) inward to the driver side releasing it from the bracket (2) notch. 8. Remove the sunshade from outside of the vehicle. Installation Procedure 1. Install the sunshade to the vehicle from the passengers side. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 15914 2. Insert the end of the sunshade (1) to the driver side bracket (2) notch. 3. Insert the sunshade (1) to the passengers side bracket (2) notch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 15915 4. Turn the sunshade cam (2) until it is aligned with the bracket (3) notch. 5. Install the sunshade. 6. Remove the suitable tool (1) from the sunshade cam locking hole (2). 7. Ensure that the sunshade cam (2) is fully seated in the bracket (3) and the sunshade slides smoothly. 8. Install the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 9. Verify the operation of the sunshade. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 15916 Sun Shade: Service and Repair Sunroof Sunshade Replacement (Crew Cab) Sunroof Sunshade Replacement (Crew Cab) Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 2. Remove the screws (1) that retain the water trough to the sunroof frame 3. Remove the water trough through the roof opening of the vehicle. 4. It is only necessary to lower the headliner. Only do those steps in the headliner replacement procedure that will lower the headline enough to gain access to the part to be remove. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 5. Remove the left and right sunroof housing drain gutters (1) from the rear of the sunroof frame (2). Refer to Sunroof Housing Drain Gutter Replacement (Extended Cab) (See: Sunroof / Moonroof Drain/Service and Repair/Removal and Replacement/Sunroof Housing Drain Gutter Replacement (Extended Cab))Sunroof Housing Drain Gutter Replacement (Crew Cab) (See: Sunroof / Moonroof Drain/Service and Repair/Removal and Replacement/Sunroof Housing Drain Gutter Replacement (Crew Cab)) 6. Slide the sunshade (3) rearward to release it from the tracks. 7. Remove the sunshade from the of the vehicle. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 15917 1. Position the front of the sunshade (3) to the rear of the sunroof frame (2). 2. Install the retaining tabs of the sunshade into the left and right sides of the track slots in the sunroof frame. 3. Slide the sunshade forward while simultaneously inserting the rear retaining tabs into the track slot 4. Ensure that the sunshade tabs are fully seated in the track slots, and the sunshade slides smoothly. 5. Install the left and right sunroof housing drain gutters (1) to the rear of the sunroof frame (2). Refer to Sunroof Housing Drain Gutter Replacement (Extended Cab) (See: Sunroof / Moonroof Drain/Service and Repair/Removal and Replacement/Sunroof Housing Drain Gutter Replacement (Extended Cab))Sunroof Housing Drain Gutter Replacement (Crew Cab) (See: Sunroof / Moonroof Drain/Service and Repair/Removal and Replacement/Sunroof Housing Drain Gutter Replacement (Crew Cab)) 6. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 7. Install the water trough to the sunroof from the top of the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the screws (1) that retain the water trough to the sunroof frame. Tighten the screws to 1 Nm (9 lb in). 9. Install the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 15918 Sun Shade: Service and Repair Sunroof Sunshade Stop Replacement Sunroof Sunshade Stop Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) Perform the Initialization/Teach Procedure any time a new sunroof motor/actuator is installed in the vehicle. 1. Press and hold the open switch until the full open position. 2. Release the switch. 3. Press and hold the open switch for 10 seconds or more. The glass panel will move further rearward of the open position, stall at the hard stop, and move back slightly to the soft stop or full open position. 4. Release the switch 5. Press and hold the open switch within 6 seconds. 6. Hold the open switch until the glass panel moves to the closed position and stops. 7. Release the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) > Page 15923 Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) Perform the Initialization/Teach Procedure any time a new sunroof motor/actuator is installed in the vehicle. 1. Press and hold the open switch until the glass panel stalls at the hard stop, then moves slightly forward. This position is called the soft stop or full open position. 2. Release the switch. 3. Press and hold the open switch within 6 seconds. 4. Hold the open switch until the glass panel moves to the closed position and stops. 5. Release the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) > Page 15924 Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) Initialization/Teach Procedure (Manual Method), New/First Time Installation Perform the initialization/teach procedure at the first operation test of the sunroof. Ensure the electrical harness on the headliner is connected to the large roof, battery power is applied and the ignition switch is on. 1. Press the sunroof switch to the VENT OPEN position until the window stall at the front hard stop in the VENT OPEN position, and then moves slightly to the soft stop position. Release the button. (This is the initialization portion). 2. Within 3 seconds, press and hold the sunroof switch-vent open again. The sunroof window will move toward and past the flush position. (This is the teach portion). 3. Continue holding the switch until the sunroof window moves to full open and then back to close and stops at the closed position. Release the button. The initialization/teach procedure is complete. 4. Verify the operation of the roof. The initialization/teach procedure is not completed if one of the following events occurs before the initialization/teach cycle is finished: * The sunroof switch is not held in the VENT OPEN position. * Ignition and/or battery power has not been removed. * Glass panel has not reached the CLOSE position. If the initialization/teach procedure is not carried out completely, it must be started again. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) > Page 15925 Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) Re-Initialization/Teach Procedure (Manual Method), possible Re-Installation Perform the initialization/teach procedure at the first operation test of the sunroof. Ensure the electrical harness on the headliner is connected to the large roof, battery power is applied and the ignition switch is on. 1. Press the sunroof switch to the VENT OPEN position until the window reaches the vent open soft stop position and release. Press the sunroof switch - vent open and hold for approximately 10 seconds, until the window stalls at the front hard stop in the vent open position, and then moves slightly to the soft stop position. Release the button. (This is the re-initialization portion.) Continue with steps 2-4. 2. Within 3 seconds, press and hold the sunroof switch-vent open again. The sunroof window will move toward and past the flush position. (This is the teach portion.) 3. Continue holding the switch until the sunroof window moves to full open and then back to close and stops at the closed position. Release the button. The initialization/teach procedure is complete. 4. Verify the operation of the roof. The initialization/teach procedure is not completed if one of the following events occurs before the initialization/teach cycle is finished: * The sunroof switch is not held in the VENT OPEN position. * Ignition and/or battery power has not been removed. * Glass panel has not reached the CLOSE position. If the initialization/teach procedure is not carried out completely, it must be started again. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor/Actuator Replacement (Extended Cab) Sunroof / Moonroof Motor: Service and Repair Sunroof Motor/Actuator Replacement (Extended Cab) Sunroof Motor/Actuator Replacement (Extended Cab) Removal Procedure Note: The sunroof motor/actuator drive shaft turns in both directions and contains no limit switches. You may replace the sunroof motor/actuator with the window panel in any position. 1. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 2. Disconnect the electrical connector (1) from the motor/actuator. 3. Remove the screws (2) from the sunroof motor/actuator. 4. Pull straight down to disengage the drive gear from the cables housed within the sunroof cable drive tubes. 5. Remove the sunroof motor/actuator (3) from the sunroof module. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor/Actuator Replacement (Extended Cab) > Page 15928 1. Position the sunroof motor/actuator (3) to the sunroof module. 2. Push the sunroof motor/actuator straight upward to engage the drive gear between the cables housed within the sunroof cable drive tubes. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sunroof motor/actuator screws (2) to the sunroof actuator. Tighten the screws to 4 Nm (35 lb in). 4. Connect the electrical connector (1) to the sunroof motor/actuator. 5. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 6. Initialize/teach the sunroof motor/actuator. Refer to Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) (See: Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) (See: Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) (See: Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) (See: Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor)). 7. Inspect the sunroof for proper operation. 8. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for programming and setup information. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor/Actuator Replacement (Extended Cab) > Page 15929 Sunroof / Moonroof Motor: Service and Repair Sunroof Motor/Actuator Replacement (Crew Cab) Sunroof Motor/Actuator Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Sunroof / Moonroof Switch: Diagrams Component Connector End Views Sunroof Switch (CF5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 15933 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (Crew Cab) Removal Procedure 1. Remove the overhead console in order to access the sunroof switch. Refer to Roof Console Replacement (See: Interior Moulding / Trim/Console/Service and Repair/Roof Console Replacement). 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat-bladed tool, carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. Installation Procedure 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. 4. Install the overhead console to the roof. Refer to Roof Console Replacement (See: Interior Moulding / Trim/Console/Service and Repair/Roof Console Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Sunroof Track Timing/Synchronization (Extended Cab) Sunroof / Moonroof Track: Service and Repair Sunroof Track Timing/Synchronization (Extended Cab) Sunroof Track Timing/Synchronization (Extended Cab) Removal Procedure 1. Place the module in the full open position. 2. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 3. Disconnect the electrical connector from the motor/actuator. 4. Remove the motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)). 5. Push the window guides rearward on the track until the guides are positioned against the rear hard stop. Installation Procedure 1. Install the motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)). 2. Connect the electrical connector to the motor/actuator. 3. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 4. Perform the Initialization/Teach Procedure. Refer to Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor)). 5. Verify the operation of the sunroof. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Sunroof Track Timing/Synchronization (Extended Cab) > Page 15938 Sunroof / Moonroof Track: Service and Repair Sunroof Track Timing/Synchronization (Crew Cab) Sunroof Track Timing/Synchronization (Crew Cab) Removal Procedure 1. Place the module in the closed/flush position. 2. Remove the sunroof window. Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 3. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 4. Disconnect the electrical connector from the motor/actuator. 5. Remove the motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)). 6. Push the cam assembly (2) forward until the timing hole (3) in the cam is aligned with the timing hole (4) in the lifter arm (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Sunroof Track Timing/Synchronization (Extended Cab) > Page 15939 7. Insert a pin (1) in the holes to hold the position while installing the drive motor. Note: Both mechanisms should now be in the closed position. 8. Repeat this procedure for the opposite side. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). Tighten the screws to 4 Nm (35 lb in). 2. Install the motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)). Tighten the motor attachment screws to 3.5 Nm (31 lb in). 3. Connect the electrical connector to the motor/actuator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Sunroof Track Timing/Synchronization (Extended Cab) > Page 15940 4. Remove the pin (1) from the holes that held the position while installing the drive motor. 5. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 6. Perform the Initialization/Teach Procedure. Refer to Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor)). 7. Verify the operation of the sunroof. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Sunroof Air Deflector Replacement (Extended Cab) Sunroof / Moonroof Windguard: Service and Repair Sunroof Air Deflector Replacement (Extended Cab) Sunroof Air Deflector Replacement (Extended Cab) Removal Procedure 1. Open the power sunroof window to the fully rear position. 2. Remove the actuators screws (1) and actuators (2) from each side of the sunroof module. 3. Remove the screws (1) attaching the sunroof air deflector (2) to the sunroof module (3). 4. Slide the air deflector rearward until it releases from the sunroof module. 5. Remove the sunroof air deflector (2) from the sunroof module (3). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Sunroof Air Deflector Replacement (Extended Cab) > Page 15945 Note: Transfer the air deflector parts to the new air deflector. 1. Position the sunroof air deflector (2) to the sunroof module (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the screws (1) attaching the sunroof air deflector (2) to the sunroof module (3). Tighten the screws to 2 Nm (18 lb in). 3. Install the actuators screws (1) and actuators (2) to each side sunroof module. Tighten the screws to 2 Nm (18 lb in). 4. Verify that the spring action of the sunroof air deflector is operating. 5. Close the sunroof window. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Sunroof Air Deflector Replacement (Extended Cab) > Page 15946 Sunroof / Moonroof Windguard: Service and Repair Sunroof Air Deflector Replacement (Crew Cab) Sunroof Air Deflector Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures Sunroof / Moonroof Drain: Procedures Sunroof Drain Inspection and Cleaning Drain Hose Routing Note: If the headliner is wet DO NOT remove any interior trim. Do the Plugged Drain Hose test first. A drain trough encircles the sunroof window panel and water is drained off by the drain hoses located at each corner of the housing. A drain channel spans across the sunroof module at the rear of the window panel and directs water into the trough. 1. The front drain hoses are routed down the windshield pillars and out the center of the pillar between the door hinges. The front hoses are installed in a rubber grommet and retained by clips. 2. The rear drain hoses are routed through the rear pillars and out of the rocker panel. In some vehicle the drain hoses are routed out through the metal roof slots and routed to the lower wheelhouse to drain out of the vehicle. The rear hoses are installed in a rubber grommet and retained by clips. Plugged Drain Hose If a waterleak has occurred check for a plugged drain hose at each corner of drainage system. 1. Open the sunroof window. 2. To test for blockage, pour a small container of water into the module housing drain trough. Check each corner to confirm the drain hose is draining water. Warning Wear safety glasses in order to avoid eye damage. 3. Use compressed air, 241 kPa (35 psi) or less to blow out any drain hose that is plugged. 4. Test the system again. 5. If the hose remains plugged, check to see it is properly routed and does not have a kink. Refer to Sunroof Housing Front Drain Hose Replacement (See: Removal and Replacement/Sunroof Housing Front Drain Hose Replacement) or Sunroof Housing Rear Drain Hose Replacement (See: Removal and Replacement/Sunroof Housing Rear Drain Hose Replacement). 6. Remove the blockage using the following steps. 1. Push mechanics wire through the hose to remove the obstruction. 2. Use compressed air in order to blow out any remaining material. Disconnected Drain Hose Inspect the drainage system for disconnected drain hoses. Complete the following steps in order to obtain partial access to drain hoses and check for a disconnected hose. 1. Open the sunroof window panel. 2. Lower the headliner as needed. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 3. Connect any disconnected hoses. 4. Ensure that the rear drain hoses are properly routed in the metal roof slot and taped in place. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 15951 Sunroof / Moonroof Drain: Removal and Replacement Sunroof Housing Drain Gutter Replacement (Extended Cab) Sunroof Housing Drain Gutter Replacement (Extended Cab) Removal Procedure Note: Tape off the perimeter of the sunroof window opening before removing the sunroof module to prevent scratching. 1. Remove the air deflector. Refer to Sunroof Air Deflector Replacement (Extended Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Extended Cab))Sunroof Air Deflector Replacement (Crew Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Crew Cab)). 2. Set the sunroof window to be in the open position of a minimum of 25 mm (1 in). Note: It is only necessary to lower the headliner. Only do those steps in headliner replacement that will lower the headliner enough to grain access. 3. Remove the sunroof module assembly. 4. Remove the screws (1) from the water gutter (2). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 15952 5. Slide the water gutter rearward to release the retaining tabs (1) from the slots (2) in the track. 6. Remove the water gutter (3) from the track. Installation Procedure 1. Position the sunroof water gutter to the sunroof window track. 2. Seat the retaining tabs (1) on the water gutter (3) into the slots (2) in the track, and push the water gutter forward until the retaining tabs lock into place. 3. Ensure that all 6 tabs are secured. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 15953 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the water gutter screws (1). Tighten the screws to 2 Nm (18 lb in). 5. Install the sunroof module. 6. Open the sunroof window to the fully open position. 7. Install the air deflector. Refer to Sunroof Air Deflector Replacement (Extended Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Extended Cab))Sunroof Air Deflector Replacement (Crew Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Crew Cab)). 8. Remove the tape from around the perimeter of the sunroof window. 9. Verify that the sunroof is operating properly. Sunroof Housing Drain Gutter Replacement (Crew Cab) Sunroof Housing Drain Gutter Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 15954 Sunroof Housing Front Drain Hose Replacement Sunroof Housing Front Drain Hose Replacement Removal Procedure 1. Remove the instrument panel trim. Refer to Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (with RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (with RPO SLT))Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (without RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (without RPO SLT)). Important: It is only necessary to lower the headliner. Only do those steps in headliner replacement that will lower the headliner enough to gain access. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 15955 2. It is only necessary to lower the headliner. Only do those steps in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 3. Disconnect the front sunroof drain hose from the sunroof module front spigot, right or left side, as needed. 4. Remove the 1 hose clips securing the drain hose to the windshield pillar, right or left side, as needed. 5. Remove the drain hose from the vehicle, right or left side, as needed. Installation Procedure 1. Install the drain hose by passing it threw the front of the dash panel. 2. Route the end of the drain hose through side cowl panel until the paint mark is visible, right or left side, as needed. 3. Install the 1 hose clips securing the drain hose to the side door frame, right or left side, as needed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 15956 4. Connect the front sunroof drain hose to the sunroof module front spigot, right or left side, as needed. 5. Install the instrument panel trim. Refer to Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (with RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (with RPO SLT))Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (without RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (without RPO SLT)). 6. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). Sunroof Housing Rear Drain Hose Replacement Sunroof Housing Rear Drain Hose Replacement Removal Procedure Important: It is only necessary to lower the headliner. Only do those steps in headliner replacement that will lower the headliner enough to grain access. 1. Lower the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 2. Disconnect the rear sunroof drain hose from the sunroof module rear spigot, right or left side, as needed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 15957 3. Remove the hose clip securing the drain hose to the vehicle, right or left side, as needed. 4. Remove the drain hose from the vehicle, right or left side, as needed. Installation Procedure 1. Route the end of the drain hose through the access hole and down the inner side panel, right or left side, as needed. 2. Install the hose clip to the door frame securing the drain hose to the vehicle, right or left side, as needed. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 15958 3. Connect the rear drain sunroof hose to the sunroof module rear spigot, right or left side, as needed. 4. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair Sunroof / Moonroof Frame: Service and Repair Sunroof Frame Replacement Removal Procedure Note: Transfer all necessary parts to the new sunroof module assembly. 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 2. Remove the sunshade. Refer to Sunroof Sunshade Replacement (Crew Cab) (See: Sun Shade/Service and Repair/Sunroof Sunshade Replacement (Crew Cab))Sunroof Sunshade Replacement (Extended Cab) (See: Sun Shade/Service and Repair/Sunroof Sunshade Replacement (Extended Cab)). 3. Remove the sunroof finish lace. Refer to Sunroof Opening Trim Finish Lace Replacement (Extended Cab) (See: Sunroof / Moonroof Interior Trim Panel/Service and Repair/Sunroof Opening Trim Finish Lace Replacement (Extended Cab)). 4. Remove the air deflector. Refer to Sunroof Air Deflector Replacement (Extended Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Extended Cab))Sunroof Air Deflector Replacement (Crew Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Crew Cab)). 5. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 6. Disconnect the front sunroof drain hoses from the drain spigot. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Page 15962 7. Disconnect the rear sunroof drain hoses from the drain spigot. 8. Remove the front to bolts located at the motor base first. 9. With the aid of an assistant, remove the remaining bolts (1) that secure the module (2) to the roof ring. Lower and remove the sunroof module assembly out through the passenger side door. 10. If you are replacing the sunroof module assembly, remove the sunroof motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)). Installation Procedure 1. If you are replacing the sunroof module assembly, install the sunroof motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Page 15963 2. With the aid of an assistant, position the sunroof module assembly to the roof ring. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 3. Install the 4 bolts (1) that secure the module (2) to the roof ring. Tighten the bolts to 10 Nm (89 lb in). 4. Install the remaining bolts at the motor base. Tighten the bolts to 10 Nm (89 lb in). 5. Connect the front and rear drain hoses to the drain spigots. 6. Install the sunshade. Refer to Sunroof Sunshade Replacement (Crew Cab) (See: Sun Shade/Service and Repair/Sunroof Sunshade Replacement (Crew Cab))Sunroof Sunshade Replacement (Extended Cab) (See: Sun Shade/Service and Repair/Sunroof Sunshade Replacement (Extended Cab)). 7. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Page 15964 Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). Verify that the electrical connector is connected to the sunroof motor/actuator. 8. Install the sunroof window. Adjust as necessary. Refer to Sunroof Window Height and Opening Fit Adjustment (Extended Cab) (See: Sunroof / Moonroof Panel/Adjustments/Sunroof Window Height and Opening Fit Adjustment (Extended Cab))Sunroof Window Height and Opening Fit Adjustment (Crew Cab) (See: Sunroof / Moonroof Panel/Adjustments/Sunroof Window Height and Opening Fit Adjustment (Crew Cab)). 9. Initialize the sunroof motor/actuator. Refer to Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor)). 10. Install the air deflector. Refer to Sunroof Air Deflector Replacement (Extended Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Extended Cab))Sunroof Air Deflector Replacement (Crew Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Crew Cab)). 11. Install the sunroof finish lace. Refer to Sunroof Opening Trim Finish Lace Replacement (Extended Cab) (See: Sunroof / Moonroof Interior Trim Panel/Service and Repair/Sunroof Opening Trim Finish Lace Replacement (Extended Cab)). 12. Inspect the sunroof for proper operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Sunroof Opening Trim Finish Lace Replacement (Extended Cab) Sunroof / Moonroof Interior Trim Panel: Service and Repair Sunroof Opening Trim Finish Lace Replacement (Extended Cab) Sunroof Opening Trim Finish Lace Replacement (Extended Cab) Removal Procedure 1. Beginning at the joint located in the center rear of the lace of the sunroof opening, pull the sunroof finishing lace from the sunroof window track assembly. 2. Remove the sunroof finishing lace from the track. Installation Procedure 1. Position the end of the sunroof finishing lace at the center rear of the sunroof opening. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Sunroof Opening Trim Finish Lace Replacement (Extended Cab) > Page 15969 2. Push the finishing lace (2) onto the track assembly flange (1) until fully seated around the sunroof opening. 3. Pull the finishing lace draw cord toward the sunroof opening. Remove the cord from the periphery of the opening. 4. Ensure that the finishing lace (2) is properly seated over the outer surface of the headliner (3). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Sunroof Opening Trim Finish Lace Replacement (Extended Cab) > Page 15970 Sunroof / Moonroof Interior Trim Panel: Service and Repair Sunroof Panel/Window Garnish Molding Replacement (Crew Cab) Sunroof Panel/Window Garnish Molding Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof / Moonroof Module: Diagrams Component Connector End Views Sunroof Control Module (CF5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Sunroof Window Height and Opening Fit Adjustment (Extended Cab) Sunroof / Moonroof Panel: Adjustments Sunroof Window Height and Opening Fit Adjustment (Extended Cab) Sunroof Window Height and Opening Fit Adjustment (Extended Cab) 1. Open the sunshade. 2. Close the sunroof window. 3. Loosen the adjusting screws on each side of the sunroof window. 4. Adjust the corners of the window panel using the following guidelines: * Adjust the front of the sunroof window flush to 2 mm (0.08 in) below the top surface of the roof panel. * Adjust the rear of the sunroof window flush to 2 mm (0.08 in) above the top surface of the roof panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the sunroof window adjustment screws. Tighten the screws to 5 Nm (44 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Sunroof Window Height and Opening Fit Adjustment (Extended Cab) > Page 15978 Sunroof / Moonroof Panel: Adjustments Sunroof Window Height and Opening Fit Adjustment (Crew Cab) Sunroof Window Height and Opening Fit Adjustment (Crew Cab) Note: Correct adjustment cannot be achieved if the sunroof window is closed from vent position. 1. Cycle the sunroof window from full open to closed position. Note: Do Not remove or lower headliner to access sunroof window screws. 2. Loosen the adjusting screws on the window. 3. Adjust the corners of the front window panel using the following guidelines: * Adjust the front of the sunroof window to 0.0 mm - 1.0 mm (0.0 in - 0.04 in ) below the top surface of the roof panel. * Adjust the rear center line of the sunroof window to 1 mm to 2 mm (0.04 in to 0.08 in ) below the top surface of the roof panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 4. Tighten the sunroof window adjustment screws. Tighten the sunroof window adjusting screws to 5 Nm (44 lb in). 5. Cycle sunroof window through all positions. 6. Inspect the sunroof window adjustment. Adjust if necessary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Sunroof Window Replacement (Crew Cab) Sunroof / Moonroof Panel: Service and Repair Sunroof Window Replacement (Crew Cab) Sunroof Window Replacement (Crew Cab) Removal Procedure Note: The sunroof must be in the fully closed position prior to removing the sunroof window. 1. Open the sunshade panel. 2. Remove the 4 screws (2) that retain the sunroof window (1) to the sunroof module assembly. 3. Remove the sunroof window from the top of the vehicle. Installation Procedure 1. Position the sunroof window (1) to the vehicle. 2. Loosely insert the screws (2) that retain the sunroof window (1) to the sunroof module assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Adjust the sunroof window panel as necessary. Refer to Sunroof Window Height and Opening Fit Adjustment (Extended Cab) (See: Adjustments/Sunroof Window Height and Opening Fit Adjustment (Extended Cab))Sunroof Window Height and Opening Fit Adjustment (Crew Cab) (See: Adjustments/Sunroof Window Height and Opening Fit Adjustment (Crew Cab)). Tighten the screws to 3 Nm (27 lb in). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Sunroof Window Replacement (Crew Cab) > Page 15981 Sunroof / Moonroof Panel: Service and Repair Sunroof Window Replacement (Extended Cab) Sunroof Window Replacement (Extended Cab) Removal Procedure 1. Position the sunshade panel fully rearward. 2. Position the sunroof window panel to the vent position. 3. Remove the sunroof window panel screws from the sunroof window panel. 4. Remove the sunroof window panel from the sunroof module. Installation Procedure 1. Position the sunroof window panel to the sunroof module. Ensure that the information logo stencil is towards the rear of the sunroof opening. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the sunroof window panel screws to the sunroof window panel. Tighten the sunroof window panel screws to 4 Nm (35 lb in). 3. Adjust the sunroof window panel as necessary. Refer to Sunroof Window Height and Opening Fit Adjustment (Extended Cab) (See: Adjustments/Sunroof Window Height and Opening Fit Adjustment (Extended Cab))Sunroof Window Height and Opening Fit Adjustment (Crew Cab) (See: Adjustments/Sunroof Window Height and Opening Fit Adjustment (Crew Cab)). 4. Inspect the sunroof window panel for proper operation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: Customer Interest Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof > Page 15990 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof > Page 15996 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Weatherstrip Replacement (Crew Cab) Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Crew Cab) Sunroof Window Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 2. Carefully remove the sunroof window weatherstrip from the perimeter of the sunroof window. Installation Procedure 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. 2. Install the sunroof window to the sunroof module assembly. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 3. Ensure that the sunroof does not have any air or waterleaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Weatherstrip Replacement (Crew Cab) > Page 15999 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Extended Cab) Sunroof Window Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 2. Carefully remove the sunroof window weatherstrip (2) from the perimeter of the sunroof window (1). Installation Procedure 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Weatherstrip Replacement (Crew Cab) > Page 16000 2. Install the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 3. Ensure that the sunroof does not have any air or waterleaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement Head Rest: Service and Repair Head Restraint Replacement Head Restraint Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement > Page 16006 Head Rest: Service and Repair Head Restraint Guide Replacement Head Restraint Guide Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement > Page 16007 Head Rest: Service and Repair Rear Seat Head Restraint Replacement Rear Seat Head Restraint Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement > Page 16008 Head Rest: Service and Repair Rear Seat Head Restraint Guide Replacement Rear Seat Head Restraint Guide Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Memory Positioning Module: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16017 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16018 Memory Positioning Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16019 Memory Seat Module (MSM) X3 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16020 Memory Seat Module (MSM) X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16021 Memory Seat Module (MSM) X5 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16022 Memory Seat Module (MSM) X6 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16023 Memory Seat Module (MSM) X7 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16024 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16025 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Seat Memory Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 16029 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 16030 Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations Power Seat Motor: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16034 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16035 Power Seat Motor: Diagrams Component Connector End Views Seat Adjuster Motor Assembly - Driver (AG1 without AN3) Seat Adjuster Motor Assembly - Driver X1 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16036 Seat Adjuster Motor Assembly - Driver X2 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16037 Seat Adjuster Motor Assembly - Passenger (AG2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16038 Seat Front Vertical Motor - Driver (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16039 Seat Front Vertical Motor - Passenger (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16040 Seat Horizontal Motor - Driver (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16041 Seat Horizontal Motor - Passenger (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16042 Seat Lumbar Horizontal Motor - Driver (AN3) Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16043 Seat Lumbar Vertical Motor - Driver (AN3) Seat Lumbar Vertical Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16044 Seat Rear Vertical Motor - Driver (HP2) Seat Rear Vertical Motor - Passenger (HP2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16045 Seat Recline Motor - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16046 Seat Recline Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16047 Power Seat Motor: Service and Repair Front Seat Adjuster Replacement (Power) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations Power Seat Motor Position Sensor: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Page 16051 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Page 16052 Power Seat Motor Position Sensor: Diagrams Component Connector End Views Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Page 16053 Seat Recline Position Sensor - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Page 16054 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: Customer Interest Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches > Page 16063 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body Sticking/Binding Door Mounted Seat Switches Power Seat Switch: All Technical Service Bulletins Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body Sticking/Binding Door Mounted Seat Switches > Page 16069 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16070 Power Seat Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16071 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16072 Power Seat Switch: Diagrams Component Connector End Views Seat Adjuster Switch - Driver (AG1 without AN3) Seat Adjuster Switch - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16073 Seat Adjuster Switch - Passenger (AG2 without AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16074 Seat Adjuster Switch - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16075 Seat Lumbar Switch - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16076 Seat Lumbar Switch - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster Switch Knob Replacement Driver or Passenger Seat Adjuster Switch Knob Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement > Page 16079 Power Seat Switch: Service and Repair Power Seat Switch Replacement Power Seat Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement > Page 16080 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement Seat Back: Service and Repair Driver or Passenger Seat Back Cushion Cover and Pad Replacement Driver or Passenger Seat Back Cushion Cover and Pad Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16085 Seat Back: Service and Repair Driver or Passenger Seat Back Cushion Frame Replacement Driver or Passenger Seat Back Cushion Frame Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16086 Seat Back: Service and Repair Front Center Seat Back Cushion Latch Upper Cover Replacement (AZ3) Front Center Seat Back Cushion Latch Upper Cover Replacement (AZ3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16087 Seat Back: Service and Repair Front Center Seat Back Cushion Latch Upper Cover Replacement (AE7) Front Center Seat Back Cushion Latch Upper Cover Replacement (AE7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16088 Seat Back: Service and Repair Driver or Passenger Seat Back Cushion Cover and Pad Replacement Driver or Passenger Seat Back Cushion Cover and Pad Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16089 Driver or Passenger Seat Back Cushion Frame Replacement Driver or Passenger Seat Back Cushion Frame Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16090 Front Center Seat Back Cushion Latch Upper Cover Replacement (AZ3) Front Center Seat Back Cushion Latch Upper Cover Replacement (AZ3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16091 Front Center Seat Back Cushion Latch Upper Cover Replacement (AE7) Front Center Seat Back Cushion Latch Upper Cover Replacement (AE7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16092 Front Center Seat Back Cushion Latch Replacement (AZ3) Front Center Seat Back Cushion Latch Replacement (AZ3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16093 Front Center Seat Back Cushion Latch Replacement (AE7) Front Center Seat Back Cushion Latch Replacement (AE7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16094 Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with AM7) Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with AM7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16095 Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with A68) Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with A68) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16096 Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab with A68) Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab with A68) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16097 Rear Seat Back Cushion Frame Replacement (Extended Cab with AM7) Rear Seat Back Cushion Frame Replacement (Extended Cab with AM7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16098 Rear Seat Back Cushion Frame Replacement (Extended Cab with A68) Rear Seat Back Cushion Frame Replacement (Extended Cab with A68) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16099 Rear Seat Back Cushion Frame Replacement (Crew Cab with A68) Rear Seat Back Cushion Frame Replacement (Crew Cab with A68) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16100 Rear Seat Back Recliner Cover Replacement (Extended Cab with A68) Rear Seat Back Recliner Cover Replacement (Extended Cab with A68) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16101 Rear Seat Back Recliner Cover Replacement (Crew Cab with A68) Rear Seat Back Recliner Cover Replacement (Crew Cab with A68) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16102 Driver or Passenger Seat Back Cushion Finish Panel Replacement Driver or Passenger Seat Back Cushion Finish Panel Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16103 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached Seat Cover: Customer Interest Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16112 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16113 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16114 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached Seat Cover: All Technical Service Bulletins Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16120 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16121 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16122 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 16127 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 16128 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of Vehicle Seat Cover: All Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of Vehicle > Page 16133 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of Vehicle > Page 16134 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of Vehicle > Page 16135 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 16141 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 16142 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 16143 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 16149 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 16150 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 16151 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached Seat Cushion: Customer Interest Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16160 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16161 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16162 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached Seat Cushion: All Technical Service Bulletins Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16168 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16169 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16170 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement Seat Cushion: Service and Repair Front Seat Cushion Center Cover Replacement Front Seat Cushion Center Cover Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16173 Seat Cushion: Service and Repair Front Seat Center Cushion Replacement Front Seat Center Cushion Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16174 Seat Cushion: Service and Repair Front Seat Cushion Rear Frame Center Cover Replacement Front Seat Cushion Rear Frame Center Cover Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16175 Seat Cushion: Service and Repair Front Seat Cushion Outer Trim Panel Replacement (Power) Front Seat Cushion Outer Trim Panel Replacement (Power) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16176 Seat Cushion: Service and Repair Front Seat Cushion Center Cover Replacement Front Seat Cushion Center Cover Replacement Front Seat Center Cushion Replacement Front Seat Center Cushion Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16177 Front Seat Cushion Rear Frame Center Cover Replacement Front Seat Cushion Rear Frame Center Cover Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16178 Front Seat Cushion Outer Trim Panel Replacement (Power) Front Seat Cushion Outer Trim Panel Replacement (Power) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16179 Front Seat Cushion Outer Trim Panel Replacement (Manual) Front Seat Cushion Outer Trim Panel Replacement (Manual) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16180 Front Seat Cushion Inner Trim Panel Replacement Front Seat Cushion Inner Trim Panel Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16181 Seat Cushion Trim Cover and Pad Replacement Seat Cushion Trim Cover and Pad Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16182 Rear Seat Cushion Cover and Pad Replacement (Extended Cab with AM7) Rear Seat Cushion Cover and Pad Replacement (Extended Cab with AM7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16183 Rear Seat Cushion Cover and Pad Replacement (Extended Cab with A68) Rear Seat Cushion Cover and Pad Replacement (Extended Cab with A68) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16184 Rear Seat Cushion Cover and Pad Replacement (Crew Cab with A68) Rear Seat Cushion Cover and Pad Replacement (Crew Cab with A68) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16185 Rear Seat Cushion Frame Replacement (Extended Cab with A68) Rear Seat Cushion Frame Replacement (Extended Cab with A68) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16186 Rear Seat Cushion Frame Replacement (Extended Cab with AM7) Rear Seat Cushion Frame Replacement (Extended Cab with AM7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16187 Rear Seat Cushion Frame Replacement (Crew Cab with A68) Rear Seat Cushion Frame Replacement (Crew Cab with A68) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16188 Rear Seat Cushion Outer Trim Panel Replacement (Extended Cab) Rear Seat Cushion Outer Trim Panel Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16189 Rear Seat Cushion Outer Trim Panel Replacement (Crew Cab) Rear Seat Cushion Outer Trim Panel Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16190 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > Customer Interest for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Fan: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > Customer Interest for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16199 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > Customer Interest for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16200 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > Customer Interest for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16201 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > Customer Interest for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16202 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Fan: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16208 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16209 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16210 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16211 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions Seat Fan: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16214 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16215 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16216 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16217 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16218 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16219 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16220 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16221 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16222 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16223 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16224 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16225 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16226 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16227 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16228 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16229 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16230 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16231 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16232 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16233 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16234 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16235 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16236 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16237 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16238 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16239 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16240 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16241 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16242 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16243 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16244 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16245 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16246 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16247 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16248 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16249 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16250 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16251 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16252 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16253 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16254 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16255 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16256 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16257 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16258 Seat Fan: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16259 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16260 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16261 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16262 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16263 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16264 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16265 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16266 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16267 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16268 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16269 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16270 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16271 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16272 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16273 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16274 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16275 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16276 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16277 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16278 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16279 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16280 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16281 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16282 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16283 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16284 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16285 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16286 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16287 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16288 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16289 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16290 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16291 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16292 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16293 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16294 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16295 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16296 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16297 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16298 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16299 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16300 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16301 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16302 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16303 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16304 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16305 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16306 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16307 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16308 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16309 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16310 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16311 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16312 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16313 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16314 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16315 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16316 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16317 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16318 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16319 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16320 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16321 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16322 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16323 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16324 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16325 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16326 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16327 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16328 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16329 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16330 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16331 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16332 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16333 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16334 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16335 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16336 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16337 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16338 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16339 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16340 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16341 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16342 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16343 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16344 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16345 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16346 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16347 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16348 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16349 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16350 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16351 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16352 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16353 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16354 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16355 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16356 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16357 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16358 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16359 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16360 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16361 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16362 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16363 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16364 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16365 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16366 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16367 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16368 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16369 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16370 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16371 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16372 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16373 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16374 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16375 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16376 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16377 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16378 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16379 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16380 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16381 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16382 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16383 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16384 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16385 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16386 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16387 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16388 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16389 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16390 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16391 Seat Fan: Electrical Diagrams Heated/Cooled Seat Schematics Heated Seat - Driver (AN3 without KB6) Heated Seat - Passenger (AN3 without KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16392 Heated/Cooled Seat Module Power and Ground (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16393 Heated/Cooled Seat - Driver (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16394 Heated/Cooled Seat - Passenger (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16395 Heated Seat - Driver (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16396 Heated Seat - Passenger (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16397 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16406 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16407 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16408 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16409 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16415 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16416 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16417 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16418 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Page 16419 Seat Heater: Specifications Fastener Tightening Specifications Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions Seat Heater: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16422 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16423 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16424 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16425 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16426 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16427 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16428 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16429 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16430 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16431 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16432 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16433 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16434 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16435 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16436 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16437 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16438 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16439 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16440 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16441 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16442 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16443 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16444 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16445 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16446 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16447 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16448 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16449 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16450 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16451 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16452 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16453 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16454 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16455 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16456 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16457 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16458 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16459 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16460 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16461 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16462 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16463 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16464 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16465 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16466 Seat Heater: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16467 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16468 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16469 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16470 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16471 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16472 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16473 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16474 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16475 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16476 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16477 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16478 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16479 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16480 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16481 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16482 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16483 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16484 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16485 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16486 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16487 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16488 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16489 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16490 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16491 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16492 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16493 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16494 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16495 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16496 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16497 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16498 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16499 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16500 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16501 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16502 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16503 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16504 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16505 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16506 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16507 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16508 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16509 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16510 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16511 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16512 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16513 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16514 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16515 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16516 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16517 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16518 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16519 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16520 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16521 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16522 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16523 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16524 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16525 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16526 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16527 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16528 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16529 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16530 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16531 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16532 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16533 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16534 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16535 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16536 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16537 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16538 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16539 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16540 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16541 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16542 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16543 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16544 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16545 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16546 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16547 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16548 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16549 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16550 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16551 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16552 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16553 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16554 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16555 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16556 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16557 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16558 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16559 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16560 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16561 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16562 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16563 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16564 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16565 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16566 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16567 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16568 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16569 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16570 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16571 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16572 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16573 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16574 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16575 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16576 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16577 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16578 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16579 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16580 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16581 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16582 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16583 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16584 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16585 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16586 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16587 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16588 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16589 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16590 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16591 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16592 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16593 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16594 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16595 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16596 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16597 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16598 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16599 Seat Heater: Connector Views Component Connector End Views Heated Seat Element - Driver Back (AN3 without KB6) Heated Seat Element - Driver Back (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16600 Heated Seat Element - Driver Cushion (AN3 without KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16601 Heated Seat Element - Driver Cushion (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16602 Heated Seat Element - Passenger Back (AN3 without KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16603 Heated Seat Element - Passenger Back (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16604 Heated Seat Element - Passenger Cushion (AN3 without KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16605 Heated Seat Element - Passenger Cushion (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16606 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16607 Seat Heater: Electrical Diagrams Heated/Cooled Seat Schematics Heated Seat - Driver (AN3 without KB6) Heated Seat - Passenger (AN3 without KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16608 Heated/Cooled Seat Module Power and Ground (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16609 Heated/Cooled Seat - Driver (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16610 Heated/Cooled Seat - Passenger (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16611 Heated Seat - Driver (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16612 Heated Seat - Passenger (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16613 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seat Seat Heater: Description and Operation Heated Seat Heated Seats Description and Operation Heated Seat Components The driver and passenger heated seat system consists of the following components: * Heated seat switch * Door lock/window switch * Memory seat module (factory installed system) * Heated seat module (dealer installed system) * Seat cushion heating element * Seat back heating element * Seat cushion temperature sensor * Seat back temperature sensor Modes of Operation The memory seat module (MSM)/heated seat module (HSM) controls heated seat operation for both the driver and passenger seats. There are 2 modes of operation available for heated seats; both the seat cushion and seat back heat, or seat back only heat. When a heated seat temperature signal request is received, the MSM/HSM will activate both the seat cushion and seat back heating elements. When the heated seat BACK ONLY mode button is pressed once the MSM/HSM will deactivate the seat cushion heating element and leave the seat back heating element ON. Factory Installed Heated Seat System Operation The driver and passenger heated seats are controlled by separate heated seat switches located in the door panels. Ground is supplied to the heated seat switches through the switch low reference circuits from their respective door lock/window switches. The door lock/window switches also control the heated seat switch heat mode and temperature indicators. The memory seat module (MSM) controls the heated seat operation for both front heated seats. The following describes the sequence of operation and how the MSM responds to each of the switch inputs. * High Temperature-When the heated seat switch is pressed once, ground is applied through the switch contacts and the switch signal circuit to the door lock/window switch indicating the high heat request. In response to this signal, the door lock/window switch applies a low current voltage through the 3 temperature indicator control circuits illuminating all 3 LEDs indicating the high temperature mode. The switch then sends a message via the GMLAN serial data line to the MSM indicating the heated seat request. The MSM then applies battery voltage through the heating element supply voltage circuit to the seat cushion and seat back heating elements. At the same time, it supplies a ground through the element low reference circuits to the seat heating elements. * Medium Temperature-When the switch is pressed a second time, the MSM sets the temperature level to medium heat. The door lock/window switch removes the voltage from the high temperature indicator leaving 2 LEDs illuminated indicating the medium temperature mode. * Low Temperature-When the switch is pressed a third time, the MSM sets the temperature level to low heat. The door lock/window switch removes the voltage from the medium temperature indicator leaving 1 LED illuminated indicating the low temperature mode. * System OFF State-When the switch is pressed a fourth time, the MSM removes the battery voltage and grounds from the heating elements. The door lock/window switch removes the voltage from the low temperature indicator, indicating the system OFF state. * Back Only Mode-When the heated seat is ON and the BACK ONLY mode button is pressed, ground is applied through the switch contacts and the heated seat back only mode signal circuit to the door lock/window switch. In response to this signal, the door lock/window switch sends a GMLAN message to the MSM indicating the back only mode request. The MSM then opens the ground path to the seat cushion heater element, leaving the seat back heater active. The door lock/window switch turns OFF the seat cushion/back mode indicator, then applies a low current voltage through the heated seat back only mode indicator control circuit illuminating the back only mode indicator. Dealer Installed Heated Seat System Operation The dealer installed driver and passenger heated seats are controlled by separate heated seat switches located in the instrument panel trim plate on the right side of the HVAC controls. The following describes the sequence of operation and how the heated seat module (HSM) responds to each of the switch inputs. * High Temperature-When the heated seat switch is pressed once, ground is applied through the switch contacts and the switch signal circuit to the HSM indicating the high heat request. In response to this signal, the HSM applies battery voltage through the heating element supply voltage circuit and ground through the element low reference circuits to the seat cushion and seat back heating elements. At the same time, the HSM applies a low current voltage through the 3 temperature indicator control circuits illuminating all 3 LEDs indicating the high temperature mode. * Medium Temperature-When the switch is pressed a second time, the HSM sets the temperature level to medium heat and removes the voltage from the high temperature indicator leaving 2 LEDs illuminated indicating the medium temperature mode. * Low Temperature-When the switch is pressed a third time, the HSM sets the temperature level to low heat and removes the voltage from the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seat > Page 16616 medium temperature indicator leaving 1 LED illuminated indicating the low temperature mode. * System OFF State-When the switch is pressed a fourth time, the HSM removes the battery voltage and grounds from the heating elements and the voltage from the low temperature indicator, indicating the system OFF state. * Back Only Mode-When the heated seat is ON and the BACK ONLY mode button is pressed, ground is applied through the switch contacts and the heated seat back only mode signal circuit to the HSM. In response to this signal, the HSM opens the ground path to the seat cushion heater element, leaving just the seat back heater active. At the same time, the HSM turns OFF the seat cushion/back mode indicator, then applies a low current voltage through the heated seat back only mode indicator control circuit illuminating the back only mode indicator. Temperature Regulation The heated seat system is designed to warm the seat cushion and seat back to 3 different temperature settings; High, MED, and Low. The MSM/HSM monitors the seat temperature through the temperature sensor signal circuits and the temperature sensors (thermistor) that are located in the seat cushion and the seat back. The temperature sensors are variable resistors, their resistance varies as the temperature of the seat changes. When the temperature sensor resistance indicates to the MSM/HSM that the seat has reached the desired temperature, the module opens the ground path of the seat heating elements through the heated seat element control circuit. The module will then cycle the element control circuit open and closed in order to maintain the desired temperature. Load Management The electrical power management function is designed to monitor the vehicle electrical load and determine when the battery is potentially in a high discharge condition. The heated seat system is one of the vehicle loads that is subject to reduction during a battery discharge condition. For more information on load management refer to Electrical Power Management Description and Operation (See: Starting and Charging/Description and Operation). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seat > Page 16617 Seat Heater: Description and Operation Heated/Cooled Seats Heated/Cooled Seats Description and Operation The driver and front passenger heated cooled seat system consist of the following components: * Seat cushion heat/cool ventilation module * Seat back heat/cool ventilation module * Climate control seat module * Memory seat module * Heated and cooled seat switch * Door lock/window switch Air Circulation When the heated/cool seat switch is pressed to initiate operation of the climate control seat system, cabin air is drawn through the heated/cool ventilation module air filter, then directed through passages in the foam of the seat cushion and seat back to the seat's occupant. In order for the climate control seat system to operate to its optimum performance, it is crucial to have unrestricted air flow through the system. A dirty or restricted air filter, the blockage of an exhaust air duct, a misaligned heated/cool ventilation module, or incorrect foam installation of the seat cushion or seat back will all have negative effects on climate control seat system operation. Seat Heat/Cool Ventilation Module Each heated/cool seat has 2 ventilation modules, one located under the seat cushion and one located in the seat back. These modules are controlled by the climate control seat module (CCSM). Each ventilation module contains a thermo-electric device (TED), a temperature sensor, and a blower motor. The TED and temperature sensor are mounted downstream of the blower motor. Each TED consists of a circuit of positive and negative connections sandwiched between 2 ceramic plates. Each ceramic plate is equipped with copper fins for heat exchange. The air flowing past these fins is either directed as conditioned air into the seat cushion and seat back, or directed into the cabin as waste air. TED is essentially a solid state heat pump that is used to heat or cool the air supply to the seat cushion and seat back. When voltage is applied to a TED, one side releases energy as heat, while the opposite side absorbs energy and gets cold. When the polarity of the current flow to the TEDs is switched, the hot and cool sides of the TED reverse. During the following climate control seat system description and operation, the TEDs, blower motors, and temperature sensors will be referenced independently even though they are all packaged together as a module. Climate Control Seat System The climate control seat system consists of two heated/cool ventilation modules and one CCSM that controls both the driver and passenger heated/cool seats systems. The CCSM is mounted below the front passenger seat cushion. Once a climate control seat system is activated, cabin air is drawn through the seat blower motors and directed across the fins of each of the TED located under the seat cushion and in the seat back. The air is either heated or cooled as it passes over the TEDs. This conditioned air is then directed through channels in the foam of the seat pad and through small holes in the seat cover to the occupant. Once the system is activated, the CCSM uses a set of algorithms to control the temperature of the selected heating or cooling modes. Climate Control Seat Module Power and Ground Battery positive voltage is supplied at all times to the CCSM through the battery positive voltage circuit and a 30 A fuse that is located in the I/P fuse block. This voltage is used by the CCSM to supply power to the TEDs and the blower motors. Ignition voltage is also supplied to the CCSM through the ignition voltage circuit and a 10 A fuse located in the underhood fuse block. The ignition voltage is used to power up the CCSM and allows the climate control seat system to operate only with the ignition in the ON position. The CCSM is grounded through the module ground circuit and G304. Climate Control Seat Module The CCSM is located under the passenger seat and controls 4 individual driver and passenger seat heat/cool ventilation blowers. When the CCSM receives a heated cooled seat command through the left or right heated/cooled seat mode signal circuit, the appropriate seat heat/cool ventilation blowers will be operated by the CCSM. Memory Seat Module The memory seat module (MSM) monitors the heated cooled seat switches through serial data message inputs and determines the heated cooled seat operating modes and temperature levels. The MSM controls the operating mode of the CCSM through 2 pulse width modulation (PWM) signal circuits. The left and right heated/cooled seat mode signal circuits are referenced from battery voltage by the CCSM and pulsed low by the MSM. Each heated Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seat > Page 16618 cooled seat is capable of operating in 3 modes with 3 temperature levels so the MSM uses 9 PWM frequencies for each signal circuit to command the heated cooled seat modes to the CCSM. Modes of Operation There are 3 modes available for climate control seat system operation, heated seat, cool seat, and back only heat operation. When a heat or cool seat mode signal request is received, the CCSM will activate both the seat cushion and seat back ventilation modules. When the seat BACK ONLY mode button is pressed once, the CCSM will deactivate the seat cushion ventilation module and leave the seat back ventilation module ON. Press the BACK ONLY mode button a second time and the CCSM will re-activate the seat cushion ventilation module. Heated/Cooled Seat Switch and Door Module The heated and cooled seat system is controlled through the heated and cooled seat switches that are located on the door panels. Ground is supplied to the heated/cool seat switch through the low reference circuit and the respective door module. The door module plays an important part of the climate control seat operation, first by relaying the selected switch inputs to the MSM, and second, by controlling the mode and temperature indicators of the heated/cool seat switch. When either a heat or cool seat switch is pressed, ground is applied through the switch contacts and the switch signal circuit to the door lock/window switch. In response to this signal, the door lock/window switch sends a serial data message to the MSM indicating the switch input. In response to this message, the MSM then sends a pulse width modulation (PWM) signal through the appropriate heated/cool seat mode signal circuit to the CCSM indicating the heated or cooled seat request. The door lock/window switch then applies a ground through the appropriate heat or cool seat indicator control circuit to the switch illuminating the selected heat or cool mode indicator. At the same time, the door lock/window switch also applies a ground through the appropriate high, medium, or low temperature indicator control circuits illuminating temperature mode indicators. Temperature Sensors As mentioned above in the heated/cool ventilation module description, the seat cushion and seat back temperature sensors are each packaged with a TED and blower motor as an assembly. The seat temperature sensors are thermistors which are attached directly to the fins of each TED. The CCSM supplies a 5 V reference voltage through the temperature sensor signal circuit and ground through the temperature sensor low reference circuit to the respective seat cushion and seat back temperature sensors. As the temperature of the TED changes, the resistance of the thermistor varies changing the feedback voltage of the temperature sensor signal circuit. This voltage varies from 0.5 - 4 V. The CCSM monitors this voltage signal to determine the fin temperature so that it can adjust and maintain the seat temperature to the selected switch input. Blower Motors Also, as mentioned above in the heated/cool ventilation module description, the seat cushion and seat back blower motors are each packaged with a TED and temperature sensor as an assembly. Each blower motor contains logic that will allow for the blower to operate only when the ignition is in the ON position. When the ignition is ON and the CCSM is powered up, the module supplies battery positive voltage through the blower supply voltage circuit to the logic of the blower motors. When the heated/cool seat switch is pressed, the CCSM applies a pre-determined voltage through the blower speed control circuits to the blower motors. The module also supplies each blower motor with a ground path through the blower low reference circuits. With the climate control seat system, the speed of the blower motor is not related directly to the High, Med, or Low input from the heated/cool seat switch. The speed of the blower motor is related directly to TED temperature as described below in heated and cooled seat operation. Heated Seat Operation When the heated seat switch is pressed for High Heat, the CCSM will transition to the HEAT state. In the heat state, the CCSM applies a pre-determined voltage through the ventilation module heat control circuits to the heat side of the TEDs, while providing a ground through the ventilation module cool control circuit to the cool side of the TEDs. A pre-determined voltage is also applied to the blower motors. The CCSM uses the following sequence beginning with the Heat SoftStart Mode to achieve the set point temperature before it can enter the Control Heat Mode. If the seat temperature is already above the Temperature Set Point, the CCSM will skip the Heat SoftStart Mode and proceed to the Control Heat Mode. * Heat SoftStart Mode - While in transition to the heat mode, the CCSM will initiate the SoftStart Mode. The intent of the Heat SoftStart Mode is for the module to bring the ventilation module fin temperature up to the pre-determined Temperature Set Point of the Max Heat Mode. The module does this by setting the blower motor speed control to a pre-determined voltage while ramping up the ventilation module voltage from 0 V to the maximum voltage, not to exceed 5 seconds, at which point the system transitions to Max Heat Mode. The Heat SoftStart Mode will only be attempted once per ignition cycle. * Max Heat Mode - Upon completion of the Heat SoftStart Mode, the CCSM will initiate Max Heat Mode. The intent of the MAX Heat Mode is to maintain the fin temperature to the pre-determined Temperature Set Point in order for the CCSM to go into the Control Heat Mode. The CCSM does this by maintaining the TED at the maximum voltage while maintaining the minimum required airflow across the fins. After max heat duration has been reached, or upon achieving the pre-determined Temperature Set Point, the system transitions to the Control Heat Mode. * Control Heat Mode - At the completion of Max Heat Mode, the CCSM will initiate Control Heat Mode. The intent of the Control Heat Mode is to maintain the desired fin temperature or the set point temperature. The CCSM does this in two ways; first by adjusting the voltage supply to the blower motor to control blower motor speed, then secondly by controlling the voltage supplied to the TED. The CCSM updates these voltages once every second. Increasing the blower motor speed will decrease the fin temperature. If the maximum blower motor speed is achieved and the fin temperature is still above the set point of high heat, the CCSM will then begin to control the TED voltage to achieve Temperature Set Point. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seat > Page 16619 Decreasing the TED voltage decreases the fin temperature. If the CCSM is trying to raise the fin temperature to set point by using TED voltage, and the fin temperature cannot be raised because the TED voltage is at the maximum, the CCSM reduces the blower motor speed to achieve the Temperature Set Point. Cooled Seat Operation When the cool seat switch is pressed for High Cool, the CCSM will transition to the COOL state. In response to this command, the CCSM applies a pre-determined voltage through the ventilation module cool control circuits to the cool side of the TEDs while providing a ground through the ventilation module heat control circuits to the heat side of the TEDs. A pre-determined voltage is also applied to the blower motors. The CCSM uses the following sequence, beginning with the Cool SoftStart Mode, to achieve the set point temperature before it can enter the Open Loop Cool Mode. * Cool SoftStart Mode - The intent of the Cool SoftStart Mode is for the CCSM to bring the TED fin temperature to maximum cool temperate. The CCSM does this by setting the blower motor speed control voltage to 0 V, while ramping up the TED voltage duty cycle from 0 V to maximum voltage duty cycle over a period not to exceed 5 seconds. Then, with the TEDs at maximum voltage, the CCSM will increase the blower speed to maximum voltage, and keep these settings for the MAX COOL DURATION. After which the system transitions to the Open Loop Cool Mode. * Open Loop Cool Mode - At the completion of Cool SoftStart Mode, the CCSM will initiate Open Loop Cool Mode. The intent of this mode is to maintain the set point fin temperature based on the input of the cool seat switch. First, by controlling the speed of the blower motor, then secondly, by controlling TED voltage. The CCSM updates these voltages once every second. Fault State The climate control seat system will operate normally in the battery voltage range of 9 - 16 V. If the system voltage falls outside of this voltage range, the module will shut down all outputs until the system returns to its normal operating voltage range. The system will also transition to the fault state per the conditions listed below, by shutting down all outputs for the seat in which the fault occurred. High Temperature Fault State During the heating or cooling modes, if the TED temperatures listed below are exceeded for more than 4 seconds, the system will enter the High Temperature Fault State. At which time the CCSM will set the TED voltage duty cycle to 0%, set the blower speed control to maximum voltage to blow ambient air over the TEDs, attempting to reduce the TED temperature below the listed maximums. The system will operate in this mode for 30 seconds. If the over temperature fault still exists after 30 seconds, the system will transition to the FAULT state for the remainder of the ignition cycle. If the over temperature fault clears, the system will then transition to the appropriate heat or cool softstart mode. The following temperatures are based upon individual readings of either sensor: * Heat mode TED temperature exceeds 230°F (110°C). * Cool mode TED temperature exceeds 149°F (65°C). Temperature Delta Fault During the heating or cooling modes, if the CCSM detects a temperature difference between the seat cushion and seat back TED temperature sensors exceeding the delta temperature listed below for more than 4 seconds, the system will enter the Temperature Delta Fault state. At which time the CCSM will set the TED voltage duty cycle to 0%, set the blower speed control to maximum voltage to blow ambient air over the TEDs, attempting to reduce the delta temperature to less than 68°F. The system will operate in this mode for 30 seconds. If the delta temperature fault still exists after 30 seconds, the system will transition to the FAULT state and remain there until the ignition has been set to OFF. * Delta between the seat cushion and seat back temperature sensors is 104°F (40°C). * This fault state is disabled in the back only mode. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling Seat Heater: Testing and Inspection Symptoms - Seat Heating and Cooling Symptoms - Seat Heating and Cooling Important: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) before using the Symptom Tables in order to verify that all of the following are true: * There are no DTCs set. * The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Heated Seats Description and Operation (See: Description and Operation). Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the system. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). Symptom List Refer to Heated Seat Inoperative (Factory Installed, KA1) (See: Heated Seat Inoperative (Factory Installed, KA1))Heated Seat Inoperative (Dealer Installed, KA1) (See: Heated Seat Inoperative (Dealer Installed, KA1)) in order to diagnose the symptom. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16622 Seat Heater: Testing and Inspection Heated Seat Inoperative (Factory Installed, KA1) Heated Seat Inoperative (Factory Installed, KA1) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The driver and front passenger heated seats are controlled by separate heated seat switches located on the door panels. When a heated seat switch is pressed, ground is momentarily applied through the switch contacts and the switch signal circuit to the door lock/window switch. In response to this signal, the door lock/window switch sends a serial message to the memory seat module (MSM) indicating the heat seat request. The MSM then applied battery voltage to the seat cushion and seat back heater elements through a common voltage supply circuit. Each individual heater element is grounded by the module through separate low side drive control circuits. The heater element control circuits are pulse width modulated (PWM) to ground by the module in order to control the seat temperatures by regulating the current flow through the heater elements. The MSM relies on 4 independent inputs from temperature sensors (thermistors) located in the seat back and seat cushion of the driver and passenger seats. The temperature sensor resistance varies based on the temperature of the heating element causing the signal circuit voltage to change. Once the seat reaches the switch set temperature, the MSM will then cycle the control circuits of the heating elements ON and OFF in order to maintain the desired seat temperature based on the feedback voltage from the sensors. The MSM then monitors the current flow through the heating elements and the of rate change of the temperature sensor to verify correct heated seat operation. Reference Information Schematic Reference Heated/Cooled Seat Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Heated Seats Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification 1. Ignition ON, observe the appropriate scan tool Driver Door Switch or Passenger Door Switch parameters listed below while pressing and releasing the appropriate switch. The readings should change between Inactive and Active. * Seat Back Heat Mode Sw. * Seat Heat Mode Sw. ‹› If not the specified values, refer to the Heated Seat Switch component test. If the heated seat switch tests normal, replace the appropriate door lock/window switch. 2. If all scan tool parameters test normal and there are no DTCs set, replace the MSM. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16623 3. If all heated seat functions operate normal and the heated seat switch indicators do not illuminate, refer to the Heated Seat Switch Indicators component test. Component Testing Heated Seat Switch 1. Ignition OFF, disconnect the X4 harness connector at the appropriate door lock/window switch. 2. Test for infinite resistance between the signal circuits listed below and the low reference circuit terminal 4 with the switch in the open position. * Seat back and cushion heat mode terminal 6 * Seat back only mode terminal 7 ‹› If not the specified value, replace the heated seat switch. 3. Test for less than 2 Ohms between the signal circuits listed below and the low reference circuit terminal 4 with the switch in the closed position. * Seat back and cushion heat mode terminal 6 * Seat back only mode terminal 7 ‹› If greater than the specified range for any of the tests, replace the heated seat switch. Heated Seat Switch Indicators 1. Ignition OFF, disconnect the X4 harness connector at the appropriate door lock/window switch. 2. Connect a 3 A fused jumper wire between the low reference circuit terminal 4 and ground. 3. Connect a test lamp between B+ and each control circuit listed below. The appropriate indicator should illuminate. * Seat back and cushion mode indicator terminal 10 * Seat back only mode indicator terminal 11 * Low heat indicator terminal 9 * Medium heat indicator terminal 1 * High heat indicator terminal 2 ‹› If any indicator does not illuminate, replace the heated seat switch. 4. If all indicators illuminate, replace the door lock/window switch. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Front Seat Heater Switch Replacement (See: Seat Heater Switch/Service and Repair/Front Seat Heater Switch Replacement) * Control Module References (See: Testing and Inspection/Programming and Relearning) for MSM and door lock/window switch replacement, programming, and setup Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16624 Seat Heater: Testing and Inspection Heated Seat Inoperative (Dealer Installed, KA1) Heated Seat Inoperative (Dealer Installed, KA1) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The driver and front passenger heated seats are controlled by separate heated seat switches. When a heated seat switch is pressed, ground is momentarily applied through the switch contacts and the switch signal circuit to the heated seat module (HSM). In response to this signal, the module then applies battery voltage through the element supply voltage circuits to the seat cushion and seat back heating elements. The HSM then supplies a ground through the appropriate indicator control circuits to the heated seat switch illuminating the switch indicators. Reference Information Schematic Reference Heated/Cooled Seat Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Heated Seats Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16625 Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification 1. Ignition ON, observe the appropriate scan tool Heated Seat Module parameter listed below while pressing and releasing the heated seat back and cushion switch. The readings should change between Off and Back & Cushion. * Driver Seat HVC Mode * Passenger Seat HVC Mode ‹› If not the specified value, refer to Heated Seat Switch Malfunction. 2. Ignition ON, observe the appropriate scan tool Heated Seat Module parameter listed below while pressing and releasing the heated seat back only switch. The readings should change between Off and Back Only. * Driver Seat HVC Mode * Passenger Seat HVC Mode ‹› If not the specified value, refer to Heated Seat Switch Malfunction. 3. If all heated seat switch functions operate OK, but, one or more of the heated seat switch indicators is inoperative or always ON, refer to Heated Seat Switch Indicator Malfunction. 4. If all scan tool parameters test normal and there are no DTCs set, replace the HSM. Circuit/System Testing Heated Seat Switch Malfunction 1. Ignition OFF, disconnect the harness connector at the appropriate heated seat switch. 2. Test for less than 10 Ohms between the ground circuit terminal 7 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Ignition ON, verify the appropriate scan tool Heated Seat Module parameter listed below is Off. * Driver Seat HVC Mode * Passenger Seat HVC Mode ‹› If not the specified value, test the signal circuits listed below for a short to ground. If the circuits test normal, replace the HSM. * Seat cushion and back signal terminal 4 * Seat back only signal terminal 5 4. Install a 3 A fused jumper wire between the signal circuit terminal 4 and ground. Verify the appropriate scan tool Heated Seat Module parameter listed below is Back & Cushion. * Driver Seat HVC Mode * Passenger Seat HVC Mode ‹› If not the specified value, test the signal circuit for a short to voltage an open/high resistance. If the circuit tests normal, replace the HSM. 5. Install a 3 A fused jumper wire between the signal circuit terminal 5 and ground. Verify the appropriate scan tool Heated Seat Module parameter listed below is Back Only. * Driver Seat HVC Mode * Passenger Seat HVC Mode ‹› If not the specified value, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the HSM. 6. If all circuits test normal, test or replace the heated seat switch. Heated Seat Switch Indicator Malfunction 1. Ignition OFF, disconnect the harness connector at the appropriate heated seat switch. 2. Ignition ON, verify that a test lamp illuminates between the control circuit terminal 2 and ground. If the test lamp does not illuminate, refer to Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16626 Interior Backlighting Malfunction (w/AN3) (See: Lighting and Horns/Testing and Inspection/Interior Backlighting Malfunction (w/AN3))Interior Backlighting Malfunction (w/o AN3) (See: Lighting and Horns/Testing and Inspection/Interior Backlighting Malfunction (w/o AN3)). 3. Ignition OFF, connect the harness connector at the heated seat switch. 4. Disconnect the X3, X4 harness connectors at the heated seat module. 5. Ignition ON, connect a test lamp between the control circuits listed below and ground. The appropriate indicator should turn ON and OFF when the test lamp is connected and disconnected. * Driver seat high heat indicator terminal 5 X3 * Driver seat medium heat indicator terminal 16 X4 * Driver seat low heat indicator terminal 4 X3 * Driver seat back and cushion heat indicator terminal 17 X4 * Driver seat back heat indicator terminal 15 X4 * Passenger seat high heat indicator terminal 10 X3 * Passenger seat medium heat indicator terminal 6 X4 * Passenger seat low heat indicator terminal 9 X3 * Passenger seat back and cushion heat indicator terminal 7 X4 * Passenger seat back heat indicator terminal 18 X4 ‹› If the test lamp is always ON, test the appropriate control circuit for a short to ground. If the circuit tests normal, test or replace the heated seat switch. ‹› If the test lamp is always OFF, test the appropriate control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, test or replace the heated seat switch. 6. If all circuits test normal, replace the HSM. Component Testing Heated Seat Switch 1. Ignition OFF, disconnect the harness connector at the heated seat switch switch. 2. Test for infinite resistance between the signal terminal 4 and the ground terminal 7 with the back and cushion switch in the open position. ‹› If not the specified value, replace the heated seat switch switch. 3. Test for infinite resistance between the signal terminal 5 and the ground terminal 7 with the back only switch in the open position. ‹› If not the specified value, replace the heated seat switch switch. 4. Test for less than 5 Ohms between the signal terminal 4 and the ground terminal 7 with the back and cushion switch in the closed position. ‹› If greater than the specified value, replace the heated seat switch. 5. Test for less than 5 Ohms between the signal terminal 5 and the ground terminal 7 with the back only switch in the closed position. ‹› If greater than the specified value, replace the heated seat switch. 6. Install a 3 A fused jumper wire between the control terminal 2 and B+. 7. Connect a test lamp between the control circuits listed below and ground. The selected indicator should illuminate. * Back and cushion heat indicator terminal 1 * Low heat indicator terminal 6 * Medium heat indicator terminal 8 * Back only heat indicator terminal 9 * High heat indicator terminal 10 ‹› If any indicator does not illuminate, replace the heated seat switch. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Control Module References (See: Testing and Inspection/Programming and Relearning)for heated seat control module replacement, setup, and programming Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16627 Seat Heater: Testing and Inspection Heated/Cooled Seats Inoperative (KB6) Heated/Cooled Seats Inoperative (KB6) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The heat and cool seat functions for the driver and passenger seats are controlled by the climate control seat module (CCSM) that is located under the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16628 passenger seat cushion. When a driver or passenger heat or cool seat switch is pressed, a low reference signal is applied through the switch signal circuit to the door lock/window switch. In response to the switch input, the door lock/window switch simultaneously illuminates the appropriate heated/cooled switch indicators and sends a serial data message to the memory seat module (MSM) indicating the heat or cool seat request. The MSM then sends a pulse width modulation (PWM) signal through the appropriate heated/cooled seat mode signal circuit to the CCSM. The CCSM then applies battery positive voltage to the seat cushion and seat back thermal electronic devices (TEDs) and a pre-determined voltage to the blower motors. To determine seat temperature, the CCSM supplies a 5 V signal and a low reference to the temperature sensors that are attached to each TED. The temperature sensors are variable resistors, their resistance changes as the temperature of the seat changes. Then based on the seat temperature, the CCSM controls the voltage level that it applies to the TEDs and blower motors. Diagnostic Aids The following conditions must be met in order to perform valid tests when diagnosing the climate control seat system: * The ignition must be cycled OFF then ON between each test in order to reset the CCSM. * Most circuit faults will set a DTC within 1.5 minutes. However, some circuit faults may cause a performance problem in one mode and be inoperative and set a DTC in another mode. In some cases it may take 5 minutes or more for a DTC to set. Operate the heated/cooled seat in each of the three modes for 5 minutes or more then check for DTCs. * The engine must be running in order to supply the CCSM with the amount of current needed to operate the heated/cool seat system. Reference Information Schematic Reference Heated/Cooled Seat Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Heated/Cooled Seats Description and Operation (See: Description and Operation/Heated/Cooled Seats) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification 1. If both, the driver and passenger heated and cooled seats are inoperative, refer to Driver and Passenger Heated/Cool Seats Inoperative. 2. Ignition ON, observe the scan tool Driver Door Switch parameters listed below while pressing and releasing the appropriate switch. The readings should change between Inactive and Active or Off and ON. * Seat Back Heat Mode Sw. * Seat Cool Mode Switch * Seat Heat Mode Sw. ‹› If the reading does not change between Inactive and Active or Off and ON, refer to the Heated and Cooled Seat Switch component test. If the switch tests normal, replace the driver door lock/window switch. ‹› If the readings test normal, but the driver heat/cool seat is inoperative, refer to Driver Heated/Cool Seat Circuit System Test. 3. Observe the scan tool Passenger Door Switch parameters listed below while pressing and releasing the appropriate switch. The readings should change between Inactive and Active or Off and ON. * Seat Back Heat Mode Sw. * Seat Cool Mode Switch * Seat Heat Mode Sw. ‹› If the reading does not change between Inactive and Active or Off and ON, refer to the Heated and Cooled Seat Switch component test. If the Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16629 switch tests normal, replace the front passenger door lock/window switch. ‹› If the readings test normal, but the passenger heat/cool seat is inoperative, refer to Passenger Heated/Cool Seat Circuit System Test. 4. If all heated and cooled seat functions operate normal, but the heated/cooled seat switch indicators do not illuminate or are always ON, refer to the Heated and Cooled Seat Switch component test. If the switch tests normal, replace the appropriate door lock/window switch. Circuit/System Testing Driver and Passenger Heated/Cool Seats Inoperative 1. Ignition OFF, disconnect the X1 harness connector at the CCSM. 2. Verify that a test lamp illuminates between the ground circuit terminal M and B+. ‹› If the test lamp does not illuminate, test the ground circuit for an open/high resistance. 3. Verify that a test lamp illuminates between the B+ circuit terminal E and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. 4. Disconnect the X2 harness connector at the CCSM. 5. Ignition ON, verify that a test lamp illuminates between the ignition circuit terminal 1 and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. 6. If all circuits test normal, replace the CCSM. Driver Heated/Cool Seat Circuit System Test 1. Ignition OFF, disconnect the X3 harness connector at the CCSM. 2. Connect a test lamp between the signal circuit terminal 14 and B+. 3. Ignition ON, press the HEAT or COOL seat switch through the high, medium, and low positions to OFF. The test lamp should illuminate until the OFF position is reached. ‹› If the test lamp does not illuminate, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the MSM. ‹› If the test lamp remains ON with the switch in the OFF position, test the signal circuit for a short to ground. If the circuit tests normal, replace the MSM. 4. Connect the X3 harness connector at the CCSM. 5. Disconnect the harness connector at the seat cushion ventilation heating and cooling module. 6. Test for less than 5 Ohms between the low reference circuit terminal 4 and ground. ‹› If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the CCSM. 7. Ignition ON, test for 4.8 - 5.2 V between the signal circuit terminal 5 and ground. ‹› If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 8. Ignition OFF then ON, connect a test lamp between the control circuits listed below and ground. Press the HEAT switch when testing the heat control circuit and the COOL switch when testing the cool control circuit. The test lamp should illuminate or slowly illuminate for approximately 2 - 4 seconds after the switch is pressed. On the heat control circuit, the test lamp may exhibit a 4 second delay before it starts to illuminate. * Seat cushion heat control circuit terminal 1 * Seat cushion cool control circuit terminal 3 ‹› If the test lamp does not illuminate, test the appropriate control circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate control circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 9. Ignition OFF then ON, connect a test lamp between the circuits listed below and ground. The test lamp should illuminate or slowly illuminate for approximately 5 seconds after pressing the HEAT switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16630 * Seat cushion blower control circuit terminal 2 * Seat cushion blower speed control circuit terminal 7 ‹› If the test lamp does not illuminate, test the appropriate circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate circuit for a short to voltage. If the circuit tests normal, replace the CCSM. 10. Ignition OFF, connect the harness connector to the seat cushion ventilation heating and cooling module. 11. Disconnect the harness connector at the seat back ventilation heating and cooling module. 12. Test for less than 5 Ohms between the low reference circuit terminal 4 and ground. ‹› If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the CCSM. 13. Ignition ON, test for 4.8 - 5.2 V between the signal circuit terminal 5 and ground. ‹› If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 14. Ignition OFF then ON, connect a test lamp between the control circuits listed below and ground. Press the HEAT switch when testing the heat control circuit and the COOL switch when testing the cool control circuit. The test lamp should illuminate or slowly illuminate for approximately 4 seconds after the switch is pressed. On the heat control circuit, the test lamp may exhibit a 4 second delay before it starts to illuminate. * Seat back heat control circuit terminal 1 * Seat back cool control circuit terminal 3 ‹› If the test lamp does not illuminate, test the appropriate control circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate control circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 15. Ignition OFF then ON, connect a test lamp between the circuits listed below and ground. The test lamp should illuminate or slowly illuminate for approximately 5 seconds after pressing the HEAT switch. * Seat back blower control circuit terminal 2 * Seat cushion blower speed control circuit terminal 7 ‹› If the test lamp does not illuminate, test the appropriate circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate circuit for a short to voltage. If the circuit tests normal, replace the CCSM. 16. If all circuits test normal, test or replace the appropriate seat cushion or seat back ventilation heating and cooling module. Passenger Heated/Cool Seat Circuit System Test 1. Ignition OFF, disconnect the X3 harness connector at the CCSM. 2. Connect a test lamp between the signal circuit terminal 6 and B+. 3. Ignition ON, press the HEAT or COOL seat switch through the high, medium, and low positions to OFF. The test lamp should illuminate until the OFF position is reached. ‹› If the test lamp does not illuminate, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the MSM. ‹› If the test lamp remains ON with the switch in the OFF position, test the signal circuit for a short to ground. If the circuit tests normal, replace the MSM. 4. Connect the X3 harness connector at the CCSM. 5. Disconnect the harness connector at the seat cushion ventilation heating and cooling module. 6. Test for less than 5 Ohms between the low reference circuit terminal 4 and ground. ‹› If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the CCSM. 7. Ignition ON, test for 4.8 - 5.2 V between the signal circuit terminal 5 and ground. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16631 ‹› If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 8. Ignition OFF then ON, connect a test lamp between the control circuits listed below and ground. Press the HEAT switch when testing the heat control circuit and the COOL switch when testing the cool control circuit. The test lamp should illuminate or slowly illuminate for approximately 2 - 4 seconds after the switch is pressed. On the heat control circuit, the test lamp may exhibit a 4 second delay before it starts to illuminate. * Seat cushion heat control circuit terminal 1 * Seat cushion cool control circuit terminal 3 ‹› If the test lamp does not illuminate, test the appropriate control circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate control circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 9. Ignition OFF then ON, connect a test lamp between the circuits listed below and ground. The test lamp should illuminate or slowly illuminate for approximately 5 seconds after pressing the HEAT switch. * Seat cushion blower control circuit terminal 2 * Seat cushion blower speed control circuit terminal 7 ‹› If the test lamp does not illuminate, test the appropriate circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate circuit for a short to voltage. If the circuit tests normal, replace the CCSM. 10. Ignition OFF, connect the harness connector to the seat cushion ventilation heating and cooling module. 11. Disconnect the harness connector at the seat back ventilation heating and cooling module. 12. Test for less than 5 Ohms between the low reference circuit terminal 4 and ground. ‹› If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the CCSM. 13. Ignition ON, test for 4.8 - 5.2 V between the signal circuit terminal 5 and ground. ‹› If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 14. Ignition OFF then ON, connect a test lamp between the control circuits listed below and ground. Press the HEAT switch when testing the heat control circuit and the COOL switch when testing the cool control circuit. The test lamp should illuminate or slowly illuminate for approximately 4 seconds after the switch is pressed. On the heat control circuit, the test lamp may exhibit a 4 second delay before it starts to illuminate. * Seat back heat control circuit terminal 1 * Seat back cool control circuit terminal 3 ‹› If the test lamp does not illuminate, test the appropriate control circuit for a short to ground or an open high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate control circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 15. Ignition OFF then ON, connect a test lamp between the circuits listed below and ground. The test lamp should illuminate or slowly illuminate for approximately 5 seconds after pressing the HEAT switch. * Seat back blower control circuit terminal 2 * Seat back blower speed control circuit terminal 7 ‹› If the test lamp does not illuminate, test the appropriate circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16632 16. If all circuits test normal, test or replace the appropriate seat cushion or seat back ventilation heating and cooling module. Component Testing Heated and Cooled Seat Switch 1. Ignition OFF, disconnect the X4 harness connector at the appropriate door lock/window switch. 2. Test for infinite resistance between the low reference circuit terminal 4 and the signal terminals listed below the with the switch in the open position. * Seat back only mode switch terminal 7 * Seat back cushion heat switch terminal 6 * Seat cool switch terminal 3 ‹› If not the specified value, replace the heated and cooled seat switch. 3. Test for less than 2 Ohms between the low reference circuit terminal 4 and the signal terminals listed below with the appropriate switch in the closed position. * Seat back only mode switch terminal 7 * Seat back cushion heat switch terminal 6 * Seat cool switch terminal 3 ‹› If greater than the specified range, replace the heated and cooled seat switch. 4. Connect a 3 A fused jumper wire between the low reference circuit terminal 4 and ground. 5. Connect a test lamp between B+ and each control terminal listed below. The appropriate indicator should illuminate. * Seat back only mode indicator terminal 11 * Seat cool mode indicator terminal 12 * Seat back and cushion indicator terminal 10 * Low temperature indicator terminal 9 * Medium temperature indicator terminal 1 * High temperature indicator terminal 2 ‹› If any indicator does not illuminate, replace the heated and cooled seat switch. Ventilation Heat and Cool Module 1. Ignition OFF, disconnect the harness connectors at the seat cushion and seat back ventilation heat and cool modules. Note: If the resistance is measured with the seat still warm or cool, the resistance values will vary. At 68°F (20°C), the nominal resistance value is 1200 Ohms ±5 percent. For warmer or cooler ambient temperatures, refer to the Temperature vs Resistance table below. The delta resistance values between the seat cushion and seat back temperature sensors should not be greater than 2000 Ohms. 2. Test for 300 Ohms - 18 kOhms between the temperature sensor signal circuit terminal 5 and the low reference circuit terminal 8. ‹› If not within the specified range, replace the ventilation heat and cool module. Note: The test leads must be connected in the correct polarity, otherwise lower out of range values will appear. Use the Positive Lead for the COOL control circuit and the Negative Lead for the HEAT control circuit. If the resistance is measured with the seat still warm or cool, the resistance values will vary even if the system was powered up for just a few seconds. The TED must be allowed to stabilize to room temperature prior to a measurement. The conditions listed below will change the resistance to out of range values: * The test leads are incorrectly connected. * Air blowing across the TED * Measuring the resistance at other than room temperature of 70°F * Holding the TED portion of the heated and cool ventilation module in your hand In warmer or cooler climates where room temperature conditions of 70°F (21°C) may be unattainable, resistance values may read above the specified range. Use a heat gun or a blower to warm or cool the TED while measuring the resistance. The resistance values should slowly lower toward the specified range. 3. Test for 0.9 - 10 Ohms between the heat control circuit terminal 1 and the cool control circuit terminal 3. ‹› If not within the specified range, replace the ventilation heat and cool module. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16633 Note: The test leads must be connected in the correct polarity, otherwise higher out of range values will appear. Use the Positive Lead for the control circuit and the Negative Lead for the ground circuit. 4. Test for 6 k - 9 kOhms between blower motor control circuit terminal 2 and the low reference circuit terminal 4. ‹› If not within the specified range, replace the ventilation heat and cool module. Note: The test leads need to be connected in the correct polarity, otherwise higher out of range values will appear. Use the Positive Lead for the speed control circuit and the Negative Lead for the ground circuit. 5. Test for 290 k - 420 kOhms between blower motor speed control circuit terminal 7 and the low reference circuit terminal 4. ‹› If not within the specified range, replace the ventilation heat and cool module. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement (Denali with KB6) (See: Service and Repair/Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement (Denali with KB6)) * Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement (Denali with KB6) (See: Service and Repair/Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement (Denali with KB6)) * Control Module References (See: Testing and Inspection/Programming and Relearning) for the MSM, CCSM, and door lock/window switch replacement, setup, and programming Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement Seat Heater: Service and Repair Driver or Passenger Seat Back Cushion Heater Replacement Driver or Passenger Seat Back Cushion Heater Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement > Page 16636 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement > Page 16637 Seat Heater: Service and Repair Driver or Passenger Seat Cushion Heater Replacement Driver or Passenger Seat Cushion Heater Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement > Page 16638 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement > Page 16639 Seat Heater: Service and Repair Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement (Denali with KB6) Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement (Denali with KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement > Page 16640 Seat Heater: Service and Repair Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement (Denali with KB6) Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement (Denali with KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement > Page 16641 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16650 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16651 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16652 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16653 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16659 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16660 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16661 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16662 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16663 Seat Heater Control Module: Diagrams Component Connector End Views Seat Back Ventilation Heating and Cooling Module - Driver (KB6) Seat Back Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16664 Seat Climate Control Module X1 (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16665 Seat Climate Control Module X2 (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16666 Seat Climate Control Module X3 (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16667 Seat Cushion Ventilation Heating and Cooling Module - Driver (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16668 Seat Cushion Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16669 Heated Seat Control Module X1 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16670 Heated Seat Control Module X2 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16671 Heated Seat Control Module X3 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16672 Heated Seat Control Module X4 (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16673 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Front Seat Heater Control Module Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Front Seat Heater Control Module Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Front Seat Heater Control Module > Page 16676 Seat Heater Control Module: Service and Repair Module Replacement - Seat Climate Control Front Seat (Denali with KB6) Module Replacement - Seat Climate Control - Front Seat (Denali with KB6) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams Seat Heater Switch: Diagrams Component Connector End Views Heated Seat Switch - Driver (SPO Heated Seats) Heated Seat Switch - Passenger (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Page 16680 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Front Seat Heater Switch Replacement Seat Heater Switch: Service and Repair Front Seat Heater Switch Replacement Front Seat Heater Switch Replacement Removal Procedure 1. Remove door upper trim panel. Refer to Upper Extension Trim Panel Replacement (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 2. Pull the door trim panel away from the door and support the bottom of the trim panel on the door panel hooks. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair)Front Side Door Trim Panel Replacement (Except YE9 or SLT) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 3. Disconnect the electrical connector. 4. Remove the front side door heater switch fasteners (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Front Seat Heater Switch Replacement > Page 16683 5. Remove the front side door heater switch assembly (2). Installation Procedure 1. Install the front side door heater switch assembly (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the front side door heater switch fasteners and tighten to 2 Nm (18 lb in). 3. Connect the electrical connector. 4. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair)Front Side Door Trim Panel Replacement (Except YE9 or SLT) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Rear Seat Latch Replacement (Extended Cab with AM7) Seat Latch: Service and Repair Rear Seat Latch Replacement (Extended Cab with AM7) Rear Seat Latch Replacement (Extended Cab with AM7) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Rear Seat Latch Replacement (Extended Cab with AM7) > Page 16688 Seat Latch: Service and Repair Rear Seat Latch Replacement (Extended Cab with A68) Rear Seat Latch Replacement (Extended Cab with A68) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Rear Seat Latch Replacement (Extended Cab with AM7) > Page 16689 Seat Latch: Service and Repair Rear Seat Latch Replacement (Crew Cab with A68) Rear Seat Latch Replacement (Crew Cab with A68) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Rear Seat Latch Replacement (Extended Cab with AM7) > Page 16690 Seat Latch: Service and Repair Front Seat Center Latch Side Belt Replacement Front Seat Center Latch Side Belt Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Rear Seat Latch Replacement (Extended Cab with AM7) > Page 16691 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair Pedal Positioning Sensor: Service and Repair Brake and Accelerator Pedal Adjuster Position Sensor Replacement (With Memory Seats) Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Disconnect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Remove the adjustable pedal position sensor bolts (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair > Page 16700 5. Remove the brake and accelerator pedal adjuster position sensor (1). Installation Procedure 1. Install the brake and accelerator pedal adjuster position sensor (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair > Page 16701 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the adjustable pedal position sensor bolts (1) and tighten to 2 Nm (18 lb in). 3. Connect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Install the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3 or DL3) Door Lock Switch - Passenger (AU3 without AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16705 Door Lock/Window Switch - Driver X1 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16706 Door Lock/Window Switch - Driver X2 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16707 Door Lock/Window Switch - Driver X3 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16708 Door Lock/Window Switch - Driver X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16709 Door Lock/Window Switch - Driver X7 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16710 Door Lock/Window Switch - Passenger X1 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16711 Door Lock/Window Switch - Passenger X2 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16712 Door Lock/Window Switch - Passenger X3 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16713 Door Lock/Window Switch - Passenger X4 (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16714 Door Lock/Window Switch - Passenger X7 (AN3 or DL3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16715 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Front (with DL8 and without SLT) Door Lock Switch Replacement - Front (with DL8 and without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) > Page 16718 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) > Page 16719 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: Customer Interest Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 16728 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 16734 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Component Connector End Views Outside Rearview Mirror Switch (DL8 or DPN) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 16738 Power Mirror Switch: Service and Repair Power Mirror Switch Replacement (with DL8 and without SLT) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations Power Seat Motor Position Sensor: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 16742 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 16743 Power Seat Motor Position Sensor: Diagrams Component Connector End Views Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 16744 Seat Recline Position Sensor - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 16745 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: Customer Interest Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches > Page 16754 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: All Technical Service Bulletins Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches > Page 16760 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16761 Power Seat Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16762 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16763 Power Seat Switch: Diagrams Component Connector End Views Seat Adjuster Switch - Driver (AG1 without AN3) Seat Adjuster Switch - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16764 Seat Adjuster Switch - Passenger (AG2 without AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16765 Seat Adjuster Switch - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16766 Seat Lumbar Switch - Driver (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16767 Seat Lumbar Switch - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster Switch Knob Replacement Driver or Passenger Seat Adjuster Switch Knob Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement > Page 16770 Power Seat Switch: Service and Repair Power Seat Switch Replacement Power Seat Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement > Page 16771 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams Seat Heater Switch: Diagrams Component Connector End Views Heated Seat Switch - Driver (SPO Heated Seats) Heated Seat Switch - Passenger (SPO Heated Seats) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 16775 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Front Seat Heater Switch Replacement Seat Heater Switch: Service and Repair Front Seat Heater Switch Replacement Front Seat Heater Switch Replacement Removal Procedure 1. Remove door upper trim panel. Refer to Upper Extension Trim Panel Replacement (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 2. Pull the door trim panel away from the door and support the bottom of the trim panel on the door panel hooks. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair)Front Side Door Trim Panel Replacement (Except YE9 or SLT) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 3. Disconnect the electrical connector. 4. Remove the front side door heater switch fasteners (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Front Seat Heater Switch Replacement > Page 16778 5. Remove the front side door heater switch assembly (2). Installation Procedure 1. Install the front side door heater switch assembly (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the front side door heater switch fasteners and tighten to 2 Nm (18 lb in). 3. Connect the electrical connector. 4. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair)Front Side Door Trim Panel Replacement (Except YE9 or SLT) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations Seat Memory Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 16782 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 16783 Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Sunroof / Moonroof Switch: Diagrams Component Connector End Views Sunroof Switch (CF5) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 16787 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (Crew Cab) Removal Procedure 1. Remove the overhead console in order to access the sunroof switch. Refer to Roof Console Replacement (See: Interior Moulding / Trim/Console/Service and Repair/Roof Console Replacement). 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat-bladed tool, carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. Installation Procedure 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. 4. Install the overhead console to the roof. Refer to Roof Console Replacement (See: Interior Moulding / Trim/Console/Service and Repair/Roof Console Replacement). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle Sound Proofing / Insulation: Customer Interest Interior - Excessive Wind Noise In Interior Of Vehicle TECHNICAL Bulletin No.: 10-08-58-001E Date: March 08, 2011 Subject: Excessive Wind Noise Coming from Rear Interior of Vehicle (Perform Repair as Outlined) Models: 2007-2011 Chevrolet Silverado Crew Cab and Extended Cab 2007-2011 GMC Sierra Crew Cab and Extended Cab Supercede: This bulletin is being revised to update the repair in the Customer Enthusiasm section and update the Parts Information. Please discard Corporate Bulletin Number 10-08-58-001D (Section 08 - Body and Accessories). Condition Some customers may comment on hearing excessive wind noise coming from the rear interior of the vehicle. Cause #1 This condition may be caused by a void in the body filler within the C-pillar. Cause #2 This condition may be caused by the body rear panel acoustic insulator that is mounted behind the rear seat. There is an access flap (1) in this panel that could cause excessive noise if the flap is not fully seated/closed into the rest of the insulator material. Also, starting in 2010, a new insulator was installed that may allow higher wind/road or other acoustic noise that may be objectionable for some customers. Noise penetration into the cab can be higher than a similarly equipped 2009, or earlier, model. As shown in the graphic above, note that the service part insulator (1) is noticeably thicker than the original 2010 part (2). Correction #1 Note This repair is specific to 2007-2010 model years. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 16796 Important Prior to attempting a repair of the vehicle, it will be necessary to compare it to a like vehicle in similar operating characteristics to determine if it should be considered normal operation or a repairable condition. 1. To properly diagnose the C-pillar body filler issue, complete the following steps: 1. Close the all doors and windows of the vehicle. 2. Without starting the vehicle, turn the vehicle ignition to the ON/RUN position. 3. Press the HVAC selector switch for Outside Air. 4. Turn the HVAC Fan Control to Medium/High. Note The air flow that is felt most commonly exits the lower C-pillar opening shown in the graphic above. 5. Run your hand alongside the lower seam of the body at the base of the C-pillar and feel for air flowing out of the bottom of the body. 6. Compare the air flow on the opposite side of the vehicle. If one side exhibits a distinct higher amount of air flow, continue on to the next step in this procedure to start the process of adding sealer to the C-pillar on that side. If no air flow difference is found, skip ahead to Correction #2. 2. To access the inner C-pillar, remove the rear seat and the body lock pillar trim panel. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Figure 1 - Outside View Through C-pillar Figure 2 - Top View, Section Cut Through C-pillar 3. Inspect the inner baffle/foam within the C-pillar for any voids in the body filler. The examples above show an opening (1) in the baffle at the forward, inboard corner of the right side C-pillar. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 16797 4. If a void is found (1), fill it with seam sealer Kent Automotive High-Tech(TM) Clear Sealer, P/N P10200 (5 oz. tube), or equivalent, to eliminate the air flow escape concern. 5. Before reinstalling the trim, inspect the insulator mat that is mounted on the body rear inner panel to ensure the access flap is fully seated/closed as shown above. 6. Reinstall the trim panels and rear seat. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Correction #2 Note This repair is ONLY for 2010 models that have the original body rear panel insulator (pictured above) and exhibit a higher noise penetration into the cab, when compared to a similarly equipped 2009, or earlier, model. Note that the insulator shape is flat across the bottom edge. Tip Before any repairs, you can visually verify which insulator the vehicle has by looking under the rear seat on the right or left side. If you can see the body Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 16798 color of the rear inner panel (shown circled above) below the insulator (1), the insulator is the original design, which is trimmed straight across the bottom. Order a service body rear panel insulator (pictured above), referencing the parts table below. Note that the new insulator has an increased thickness and the height was extended on both ends. R & R the rear seat and any necessary trim to replace the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Further Repair for Customer Enthusiasm Only in situations when the above repairs are completed and the customer is still commenting on objectionable noise, the following additional steps can be done to sound-proof the body rear panel. This additional sound-proofing should only be done in cases deemed necessary for customer enthusiasm. Note After this procedure has been performed, the vehicle needs to be re-assembled and evaluated with the trim and rear seat fully installed in the vehicle. If the bulletin has been followed properly, the noise should be reduced to a level quieter than stock 2011 models, and no further repairs should be attempted. It has been found that controlling the wind noise at the two pressure relief valve (PRV) locations is the key to quieting the rear cab wind noise. The repair below has been found to be successful in eliminating most of the objectionable noise. 1. R & R the rear seat and any necessary trim to remove the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Note GM P/N 12378195 is not available in Canada. However several equivalents such as *Evercoat (Q-Pads) P/N 100116 and *Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. 2. Install noise and vibration sound deadening pads to backside of the body rear panel insulator. Follow the pattern shown above, ensuring they cover the two PRV locations. Use GM P/N 12378195, or equivalents commercially available through *Dynamat(R), Evercoat(R) or Dominion Sure Seal. Important Ensure that the foam tape pattern does not have any gaps in the corners and that it is securely pressed/attached to the inner rear body panel. 3. Install *Duck Brand Weatherstrip Seal (Self Adhesive Foam) P/N 1278750, or equivalent, to the inner body rear end panel following the patterns shown below: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 16799 Note Ensure that the cross-car adhesive foam is positioned at a height just below the insulator push pin fastener locations so that once the fasteners are installed, the seal is compressed. - Across the inner rear body panel, matching the width of the insulator panel. - Downward from each end of the cross-car foam (left side (1) shown in the graphic above). The length should match the height of the insulator panel. - Partially around the two PRV's. Install the foam down the outboard side (1), underneath (2), partially back up the inboard side (3), then finish with a length extending further inboard (4) from the PRV. Important Ensure that any C-pillar wiring harnesses/connectors are routed forward of the insulator, and not trapped behind it. 4. Position the body rear panel insulator to the inner rear body panel and install the push pin retainers. Caution should be taken to not disturb the foam tape installed previously. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 16800 Important Ensure that the foam is securely wedged between the outboard edges of the insulator and the wiring harnesses/sheet metal, making sure that any C-pillar wiring harnesses/connectors are routed forward of the insulator and foam, and not trapped behind either of them. 5. Install a length of *Duck Brand Window Air Conditioner Insulating Strip Seal P/N 1284075, or equivalent, down each side C-pillar. 6. Complete the installation of the insulator panel and interior trim. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Contact Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Duck Brand products, or equivalent, can be obtained from your local hardware or home improvement store. *GM‹›P/N‹›12378195 is not available in Canada. However several equivalents such as Evercoat (Q-Pads) P/N 100116 and Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 can be obtained by contacting Dominion Sure Seal at 1-800-265-0790. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior Excessive Wind Noise In Interior Of Vehicle Sound Proofing / Insulation: All Technical Service Bulletins Interior - Excessive Wind Noise In Interior Of Vehicle TECHNICAL Bulletin No.: 10-08-58-001E Date: March 08, 2011 Subject: Excessive Wind Noise Coming from Rear Interior of Vehicle (Perform Repair as Outlined) Models: 2007-2011 Chevrolet Silverado Crew Cab and Extended Cab 2007-2011 GMC Sierra Crew Cab and Extended Cab Supercede: This bulletin is being revised to update the repair in the Customer Enthusiasm section and update the Parts Information. Please discard Corporate Bulletin Number 10-08-58-001D (Section 08 - Body and Accessories). Condition Some customers may comment on hearing excessive wind noise coming from the rear interior of the vehicle. Cause #1 This condition may be caused by a void in the body filler within the C-pillar. Cause #2 This condition may be caused by the body rear panel acoustic insulator that is mounted behind the rear seat. There is an access flap (1) in this panel that could cause excessive noise if the flap is not fully seated/closed into the rest of the insulator material. Also, starting in 2010, a new insulator was installed that may allow higher wind/road or other acoustic noise that may be objectionable for some customers. Noise penetration into the cab can be higher than a similarly equipped 2009, or earlier, model. As shown in the graphic above, note that the service part insulator (1) is noticeably thicker than the original 2010 part (2). Correction #1 Note This repair is specific to 2007-2010 model years. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior Excessive Wind Noise In Interior Of Vehicle > Page 16806 Important Prior to attempting a repair of the vehicle, it will be necessary to compare it to a like vehicle in similar operating characteristics to determine if it should be considered normal operation or a repairable condition. 1. To properly diagnose the C-pillar body filler issue, complete the following steps: 1. Close the all doors and windows of the vehicle. 2. Without starting the vehicle, turn the vehicle ignition to the ON/RUN position. 3. Press the HVAC selector switch for Outside Air. 4. Turn the HVAC Fan Control to Medium/High. Note The air flow that is felt most commonly exits the lower C-pillar opening shown in the graphic above. 5. Run your hand alongside the lower seam of the body at the base of the C-pillar and feel for air flowing out of the bottom of the body. 6. Compare the air flow on the opposite side of the vehicle. If one side exhibits a distinct higher amount of air flow, continue on to the next step in this procedure to start the process of adding sealer to the C-pillar on that side. If no air flow difference is found, skip ahead to Correction #2. 2. To access the inner C-pillar, remove the rear seat and the body lock pillar trim panel. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Figure 1 - Outside View Through C-pillar Figure 2 - Top View, Section Cut Through C-pillar 3. Inspect the inner baffle/foam within the C-pillar for any voids in the body filler. The examples above show an opening (1) in the baffle at the forward, inboard corner of the right side C-pillar. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior Excessive Wind Noise In Interior Of Vehicle > Page 16807 4. If a void is found (1), fill it with seam sealer Kent Automotive High-Tech(TM) Clear Sealer, P/N P10200 (5 oz. tube), or equivalent, to eliminate the air flow escape concern. 5. Before reinstalling the trim, inspect the insulator mat that is mounted on the body rear inner panel to ensure the access flap is fully seated/closed as shown above. 6. Reinstall the trim panels and rear seat. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Correction #2 Note This repair is ONLY for 2010 models that have the original body rear panel insulator (pictured above) and exhibit a higher noise penetration into the cab, when compared to a similarly equipped 2009, or earlier, model. Note that the insulator shape is flat across the bottom edge. Tip Before any repairs, you can visually verify which insulator the vehicle has by looking under the rear seat on the right or left side. If you can see the body Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior Excessive Wind Noise In Interior Of Vehicle > Page 16808 color of the rear inner panel (shown circled above) below the insulator (1), the insulator is the original design, which is trimmed straight across the bottom. Order a service body rear panel insulator (pictured above), referencing the parts table below. Note that the new insulator has an increased thickness and the height was extended on both ends. R & R the rear seat and any necessary trim to replace the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Further Repair for Customer Enthusiasm Only in situations when the above repairs are completed and the customer is still commenting on objectionable noise, the following additional steps can be done to sound-proof the body rear panel. This additional sound-proofing should only be done in cases deemed necessary for customer enthusiasm. Note After this procedure has been performed, the vehicle needs to be re-assembled and evaluated with the trim and rear seat fully installed in the vehicle. If the bulletin has been followed properly, the noise should be reduced to a level quieter than stock 2011 models, and no further repairs should be attempted. It has been found that controlling the wind noise at the two pressure relief valve (PRV) locations is the key to quieting the rear cab wind noise. The repair below has been found to be successful in eliminating most of the objectionable noise. 1. R & R the rear seat and any necessary trim to remove the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Note GM P/N 12378195 is not available in Canada. However several equivalents such as *Evercoat (Q-Pads) P/N 100116 and *Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. 2. Install noise and vibration sound deadening pads to backside of the body rear panel insulator. Follow the pattern shown above, ensuring they cover the two PRV locations. Use GM P/N 12378195, or equivalents commercially available through *Dynamat(R), Evercoat(R) or Dominion Sure Seal. Important Ensure that the foam tape pattern does not have any gaps in the corners and that it is securely pressed/attached to the inner rear body panel. 3. Install *Duck Brand Weatherstrip Seal (Self Adhesive Foam) P/N 1278750, or equivalent, to the inner body rear end panel following the patterns shown below: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior Excessive Wind Noise In Interior Of Vehicle > Page 16809 Note Ensure that the cross-car adhesive foam is positioned at a height just below the insulator push pin fastener locations so that once the fasteners are installed, the seal is compressed. - Across the inner rear body panel, matching the width of the insulator panel. - Downward from each end of the cross-car foam (left side (1) shown in the graphic above). The length should match the height of the insulator panel. - Partially around the two PRV's. Install the foam down the outboard side (1), underneath (2), partially back up the inboard side (3), then finish with a length extending further inboard (4) from the PRV. Important Ensure that any C-pillar wiring harnesses/connectors are routed forward of the insulator, and not trapped behind it. 4. Position the body rear panel insulator to the inner rear body panel and install the push pin retainers. Caution should be taken to not disturb the foam tape installed previously. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior Excessive Wind Noise In Interior Of Vehicle > Page 16810 Important Ensure that the foam is securely wedged between the outboard edges of the insulator and the wiring harnesses/sheet metal, making sure that any C-pillar wiring harnesses/connectors are routed forward of the insulator and foam, and not trapped behind either of them. 5. Install a length of *Duck Brand Window Air Conditioner Insulating Strip Seal P/N 1284075, or equivalent, down each side C-pillar. 6. Complete the installation of the insulator panel and interior trim. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Contact Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Duck Brand products, or equivalent, can be obtained from your local hardware or home improvement store. *GM‹›P/N‹›12378195 is not available in Canada. However several equivalents such as Evercoat (Q-Pads) P/N 100116 and Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 can be obtained by contacting Dominion Sure Seal at 1-800-265-0790. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Splash Guard > Component Information > Service and Repair > Engine Splash Shield Replacement - Left Side Splash Guard: Service and Repair Engine Splash Shield Replacement - Left Side Engine Splash Shield Replacement - Left Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Splash Guard > Component Information > Service and Repair > Engine Splash Shield Replacement - Left Side > Page 16815 Splash Guard: Service and Repair Engine Splash Shield Replacement - Right Side Engine Splash Shield Replacement - Right Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Service and Repair > Front Air Deflector Extension Replacement Air Dam: Service and Repair Front Air Deflector Extension Replacement Front Air Deflector Extension Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Service and Repair > Front Air Deflector Extension Replacement > Page 16821 Air Dam: Service and Repair Front Air Deflector Replacement Front Air Deflector Replacement (Chevrolet) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Rear Spoiler Replacement (Avalanche) Spoiler: Service and Repair Rear Spoiler Replacement (Avalanche) Rear Spoiler Replacement (Avalanche) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Rear Spoiler Replacement (Avalanche) > Page 16826 Spoiler: Service and Repair Rear Spoiler Replacement (Sierra / Silverado) Rear Spoiler Replacement (Sierra Silverado) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and Repair > Endgate Torque Rod Replacement Tailgate Hinge: Service and Repair Endgate Torque Rod Replacement Endgate Torque Rod Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and Repair > Endgate Torque Rod Replacement > Page 16832 Tailgate Hinge: Service and Repair Endgate Lower Hinge Replacement - Body Side Endgate Lower Hinge Replacement - Body Side Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Pickup Box Endgate Latch Rod Replacement (Pickup Box) Tailgate Latch: Service and Repair Pickup Box Endgate Latch Rod Replacement (Pickup Box) Pickup Box Endgate Latch Rod Replacement (Pickup Box) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Pickup Box Endgate Latch Rod Replacement (Pickup Box) > Page 16837 Tailgate Latch: Service and Repair Pickup Box Endgate Striker Replacement (Pickup Box) Pickup Box Endgate Striker Replacement (Pickup Box) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Pickup Box Endgate Latch Rod Replacement (Pickup Box) > Page 16838 Tailgate Latch: Service and Repair Endgate Latch Replacement Endgate Latch Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair Tailgate Release Handle: Service and Repair Endgate Handle Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair > Endgate Cable Replacement Tailgate Shock / Support: Service and Repair Endgate Cable Replacement Endgate Cable Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair > Endgate Cable Replacement > Page 16846 Tailgate Shock / Support: Service and Repair Pickup Box Endgate Cable Bolt Replacement Pickup Box Endgate Cable Bolt Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Tie Down Hook / Bracket > Component Information > Service and Repair Tie Down Hook / Bracket: Service and Repair Pickup Box Tie Down Loop Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning (See: Service Precautions/Technician Safety Information/Approved Equipment for Collision Repair Warning). 1. Locate and drill out the spot welds. 2. Remove the tie down loop. Installation Procedure 1. Prepare all mating surfaces as necessary. 2. Apply GM-approved Weld-Thru coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair (). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Tie Down Hook / Bracket > Component Information > Service and Repair > Page 16850 3. Position the tie down loop. 4. Plug weld accordingly. 5. Clean and prepare all welded surfaces. 6. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (). 7. Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems (See: Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement (1500/2500 Series) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > Customer Interest for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch Truck Bed Cover Latch: Customer Interest Body - Soft Tonneau Cover Appears Loose/Won't Latch TECHNICAL Bulletin No.: 09-08-66-004A Date: January 04, 2011 Subject: Roll Up Soft Tonneau Cover Appears Loose or Latch Not Functioning Properly (Adjust Upper Side Rail Clamps and/or Rails and/or Replace Rear Latch) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Attention: This bulletin only applies to vehicles with tonneau part numbers 19213900, 19213901, 19213902, 19213903, 19213904 and 19213905. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the roll up soft tonneau cover is too loose, or that the tonneau cover latch is disengaging and not staying closed. Two improvements have been implemented since the original release of the tonneau cover. Be sure that the tonneau cover meets the criteria of the items below. Cause #1 The condition may be caused by improper installation of one or more of the upper side rail clamps. Using the outer groove (1) when a molded bed rail protector IS NOT installed may cause a gap (2) between the pad and pickup box. This may also prevent proper latch retention. Correction #1 Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > Customer Interest for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch > Page 16864 A removable insert, shown above, was added to the outer groove of the upper side rail clamp to help prevent improper positioning from unintentionally occurring. Check that the clamps are properly installed using the correct groove in the upper side rail clamp. Correct positioning is detailed in the illustration above. Cause #2 The condition may be caused by the tonneau bows not falling into proper position when the tonneau cover is rolled out. This cause would indicate that repositioning on an upper side rail clamp is needed. Correction #2 Note the position of the bows and use the appropriate repair below: - If bows do not fit between the side rails and additional clearance is required, remove the clamp nearest the interference. Remove the orange strip to allow access to the outer groove of the upper clamp. Reinstall the clamp, using the outer groove of the upper clamp. - If bows are too loose, adjust the clamp nearest the bow with excessive clearance to the inner groove of the upper clamp. Cause #3 This condition may be caused by a misalignment of the tonneau side rails and/or improper adjustment of the forward tension screws. The graphic above shows a misalignment of the tonneau side rail (1) to the front of the pickup box (2). Correction #3 1. Verify that the tonneau side rails are aligned with the front of the pickup box as shown above. 2. Ensure that the side rails are aligned with each other in the same fore/aft position (1) on the vehicle. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > Customer Interest for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch > Page 16865 Vinyl contains unique thermal properties that cause it to expand in cold conditions and retract during hot conditions. Under recommended install temperatures of 21°C (70°F), the tension screws should be adjusted as shown below. Important Be sure to adjust both sides to the same tension. 3. Inspect and verify that the tension screws are adjusted to the 4.76 mm (3/16 in) gap shown in the illustration above. If adjustment is necessary to tighten, turn the screw clockwise with the 1/4 inch key provided. Cause #4 The condition may be caused by over travel of the latch during operation, causing the latch spring to bind. Correction #4 Note A new design of the latch system now contains a latch stop (1) to limit the travel of the latch during operation. This new latch stop prevents over travel and keeps the spring from binding. Verify that the latch system contains a latch stop, noted in the illustration above. If the stop IS NOT present, replace the latch system with latch spring stop service kit, P/N 19213898 and a new latch assembly service kit, P/N 19201885. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > Customer Interest for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch > Page 16866 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > Customer Interest for Truck Bed Cover Latch: > 09-08-66-003A > Dec > 10 > Body - Tonneau Cover Fits To Loose On Vehicle Truck Bed Cover Latch: Customer Interest Body - Tonneau Cover Fits To Loose On Vehicle TECHNICAL Bulletin No.: 09-08-66-003A Date: December 23, 2010 Subject: One-Piece Hard Tonneau Cover Fits Loose on Vehicle or Rear Tonneau Latch Not Functioning Properly (Adjust Rear Latch and Align Tonneau Cover) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-003 (Section 08 - Body and Accessories). Condition Some customers may comment that the hard tonneau rear latch is not functioning properly or that the tonneau cover is loose on the vehicle, causing noticeable movement during vehicle operation. Cause This condition may be caused by both sides of the latch not engaging or releasing at the same time, or the tonneau frame may be misaligned. Correction Note The tonneau cover latches contain multiple design features to accommodate for build variation of the pickup box and tonneau cover. Use the following repair process to obtain proper latch operation: Inspect/Adjust Latch to Striker Loop Interface Side to Side Adjustment 1. Lower the endgate. 2. Slowly lower the tonneau cover from the open to closed position. Use caution not to drop or slam the tonneau cover closed as this may damage the latch assembly. 3. Inspect the fit of the latch into the striker loop just before the U-shaped catch is engaged. The latch should fit into the striker loop without contacting any portion of the rear bracket or striker loop. If contact is observed, proceed with the following steps: 1. Loosen the two nuts of the rotary latch that is making contact to the striker loop assembly with a 7/16 inch wrench. 2. Slide the rotary latch side to side until the latch freely falls into the rear striker loop. 3. Tighten the rotary latch nuts to 2.26 Nm (20 lb in). 4. Inspect the operation of the latches by turning the twist handle. If the latches do not close or release properly, adjust the latch wire per the Inspect/Adjust Latch Release Operation section of this document. Up and Down Adjustment 1. Lower the endgate. 2. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 3. Inspect the fit of the tonneau cover side seal to the pickup box. If the seal does not have complete contact, lower the striker loop until the seal has complete contact using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Lower the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). 4. Inspect for seal contact and repeat procedure as necessary. 4. Close the endgate. 5. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 6. Inspect that both latches have engaged by lifting up on the corner of the tonneau. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > Customer Interest for Truck Bed Cover Latch: > 09-08-66-003A > Dec > 10 > Body - Tonneau Cover Fits To Loose On Vehicle > Page 16871 7. Repeat steps 5 and 6 five more times to look for repeatability. If either one of the sides does not engage, manually close the latch that did not engage and inspect the latch closure of each side by wiggling each corner. Check for the following: 1. If one side is too loose and exhibiting excessive movement, lower the corresponding loop per steps 3.1-3.4 in the Up and Down Adjustment section above. 2. If one side requires excess manual efforts to close, raise the corresponding loop using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Raise the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). Inspect/Adjust Latch Release Operation 1. Open the tonneau cover. 2. Manually push the U-shaped catches closed for both sides of the vehicle. If either one of the catches does not close, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Push the cable inboard from the end of cable to add length to the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should engage at the same time. 4. Inspect the timing of the latch engagement by manually closing the latches and twisting the lock handle with the cover in the open position. If the latches do not engage at the same time, repeat the above adjustment until they do. 3. Twist the handle and listen for the latches to release. If either one of the catches does not open, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Pull the cable outboard from the end of the cable to shorten the length of the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should release at the same time. 4. Inspect the timing of latch release. Repeat steps 3.1-3.3 above, adjusting the latch that releases second, until both latches are releasing at the same time. Verify that the front frame is centered and squared onto the pickup box 1. Measure from the edge of the front panel sheet metal cross-car to the edge of the hinge clip on both sides. Loosen hardware and adjust the frame position side to side until it's centered. 2. Measure from the stack pocket to the end of the side frame on both sides. Loosen hardware and adjust the frame position until both sides match. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch Truck Bed Cover Latch: All Technical Service Bulletins Body - Soft Tonneau Cover Appears Loose/Won't Latch TECHNICAL Bulletin No.: 09-08-66-004A Date: January 04, 2011 Subject: Roll Up Soft Tonneau Cover Appears Loose or Latch Not Functioning Properly (Adjust Upper Side Rail Clamps and/or Rails and/or Replace Rear Latch) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Attention: This bulletin only applies to vehicles with tonneau part numbers 19213900, 19213901, 19213902, 19213903, 19213904 and 19213905. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the roll up soft tonneau cover is too loose, or that the tonneau cover latch is disengaging and not staying closed. Two improvements have been implemented since the original release of the tonneau cover. Be sure that the tonneau cover meets the criteria of the items below. Cause #1 The condition may be caused by improper installation of one or more of the upper side rail clamps. Using the outer groove (1) when a molded bed rail protector IS NOT installed may cause a gap (2) between the pad and pickup box. This may also prevent proper latch retention. Correction #1 Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch > Page 16877 A removable insert, shown above, was added to the outer groove of the upper side rail clamp to help prevent improper positioning from unintentionally occurring. Check that the clamps are properly installed using the correct groove in the upper side rail clamp. Correct positioning is detailed in the illustration above. Cause #2 The condition may be caused by the tonneau bows not falling into proper position when the tonneau cover is rolled out. This cause would indicate that repositioning on an upper side rail clamp is needed. Correction #2 Note the position of the bows and use the appropriate repair below: - If bows do not fit between the side rails and additional clearance is required, remove the clamp nearest the interference. Remove the orange strip to allow access to the outer groove of the upper clamp. Reinstall the clamp, using the outer groove of the upper clamp. - If bows are too loose, adjust the clamp nearest the bow with excessive clearance to the inner groove of the upper clamp. Cause #3 This condition may be caused by a misalignment of the tonneau side rails and/or improper adjustment of the forward tension screws. The graphic above shows a misalignment of the tonneau side rail (1) to the front of the pickup box (2). Correction #3 1. Verify that the tonneau side rails are aligned with the front of the pickup box as shown above. 2. Ensure that the side rails are aligned with each other in the same fore/aft position (1) on the vehicle. Note Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch > Page 16878 Vinyl contains unique thermal properties that cause it to expand in cold conditions and retract during hot conditions. Under recommended install temperatures of 21°C (70°F), the tension screws should be adjusted as shown below. Important Be sure to adjust both sides to the same tension. 3. Inspect and verify that the tension screws are adjusted to the 4.76 mm (3/16 in) gap shown in the illustration above. If adjustment is necessary to tighten, turn the screw clockwise with the 1/4 inch key provided. Cause #4 The condition may be caused by over travel of the latch during operation, causing the latch spring to bind. Correction #4 Note A new design of the latch system now contains a latch stop (1) to limit the travel of the latch during operation. This new latch stop prevents over travel and keeps the spring from binding. Verify that the latch system contains a latch stop, noted in the illustration above. If the stop IS NOT present, replace the latch system with latch spring stop service kit, P/N 19213898 and a new latch assembly service kit, P/N 19201885. Warranty Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch > Page 16879 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Truck Bed Cover Latch: > 09-08-66-003A > Dec > 10 > Body - Tonneau Cover Fits To Loose On Vehicle Truck Bed Cover Latch: All Technical Service Bulletins Body - Tonneau Cover Fits To Loose On Vehicle TECHNICAL Bulletin No.: 09-08-66-003A Date: December 23, 2010 Subject: One-Piece Hard Tonneau Cover Fits Loose on Vehicle or Rear Tonneau Latch Not Functioning Properly (Adjust Rear Latch and Align Tonneau Cover) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-003 (Section 08 - Body and Accessories). Condition Some customers may comment that the hard tonneau rear latch is not functioning properly or that the tonneau cover is loose on the vehicle, causing noticeable movement during vehicle operation. Cause This condition may be caused by both sides of the latch not engaging or releasing at the same time, or the tonneau frame may be misaligned. Correction Note The tonneau cover latches contain multiple design features to accommodate for build variation of the pickup box and tonneau cover. Use the following repair process to obtain proper latch operation: Inspect/Adjust Latch to Striker Loop Interface Side to Side Adjustment 1. Lower the endgate. 2. Slowly lower the tonneau cover from the open to closed position. Use caution not to drop or slam the tonneau cover closed as this may damage the latch assembly. 3. Inspect the fit of the latch into the striker loop just before the U-shaped catch is engaged. The latch should fit into the striker loop without contacting any portion of the rear bracket or striker loop. If contact is observed, proceed with the following steps: 1. Loosen the two nuts of the rotary latch that is making contact to the striker loop assembly with a 7/16 inch wrench. 2. Slide the rotary latch side to side until the latch freely falls into the rear striker loop. 3. Tighten the rotary latch nuts to 2.26 Nm (20 lb in). 4. Inspect the operation of the latches by turning the twist handle. If the latches do not close or release properly, adjust the latch wire per the Inspect/Adjust Latch Release Operation section of this document. Up and Down Adjustment 1. Lower the endgate. 2. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 3. Inspect the fit of the tonneau cover side seal to the pickup box. If the seal does not have complete contact, lower the striker loop until the seal has complete contact using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Lower the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). 4. Inspect for seal contact and repeat procedure as necessary. 4. Close the endgate. 5. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 6. Inspect that both latches have engaged by lifting up on the corner of the tonneau. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Truck Bed Cover Latch: > 09-08-66-003A > Dec > 10 > Body - Tonneau Cover Fits To Loose On Vehicle > Page 16884 7. Repeat steps 5 and 6 five more times to look for repeatability. If either one of the sides does not engage, manually close the latch that did not engage and inspect the latch closure of each side by wiggling each corner. Check for the following: 1. If one side is too loose and exhibiting excessive movement, lower the corresponding loop per steps 3.1-3.4 in the Up and Down Adjustment section above. 2. If one side requires excess manual efforts to close, raise the corresponding loop using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Raise the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). Inspect/Adjust Latch Release Operation 1. Open the tonneau cover. 2. Manually push the U-shaped catches closed for both sides of the vehicle. If either one of the catches does not close, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Push the cable inboard from the end of cable to add length to the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should engage at the same time. 4. Inspect the timing of the latch engagement by manually closing the latches and twisting the lock handle with the cover in the open position. If the latches do not engage at the same time, repeat the above adjustment until they do. 3. Twist the handle and listen for the latches to release. If either one of the catches does not open, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Pull the cable outboard from the end of the cable to shorten the length of the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should release at the same time. 4. Inspect the timing of latch release. Repeat steps 3.1-3.3 above, adjusting the latch that releases second, until both latches are releasing at the same time. Verify that the front frame is centered and squared onto the pickup box 1. Measure from the edge of the front panel sheet metal cross-car to the edge of the hinge clip on both sides. Loosen hardware and adjust the frame position side to side until it's centered. 2. Measure from the stack pocket to the end of the side frame on both sides. Loosen hardware and adjust the frame position until both sides match. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Component Information > Technical Service Bulletins > Accessories - Pick Up Box Accessory Mounting Information Truck Bed Storage Compartment: Technical Service Bulletins Accessories - Pick Up Box Accessory Mounting Information INFORMATION Bulletin No.: 09-08-66-011A Date: October 04, 2010 Subject: Information on Mounting Points for Pickup Box Accessories Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-011 (08 - Body and Accessories). The pickup box was designed for the use of add-on equipment. However there are specific mounting points that must be used along with weight restrictions, refer to the following: Chart 1 Weight Restrictions for Pickup Box Add-Ons. Structural members have been added to provide load paths directly to the platform cross-sills and into the vehicle frame. Aftermarket accessories should take advantage of these intended load paths as detailed below in Figures 1-4. Depending on the accessory design, it may be necessary to add some form of a spacer under the accessories at the structural hard points to take up any gap. Do not use the GM Cargo Management Option mounting points for attaching anything other than the GM Cargo Management system as referenced in Figure 5. Figure 1 - Side View - Structural Members Figure 2 - Top View - Structural Members Figure 3 - Top View - Front Structure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Component Information > Technical Service Bulletins > Accessories - Pick Up Box Accessory Mounting Information > Page 16889 Figure 4 - Top View - Rear Structure Figure 5 - GM Cargo Management Points Caution Overloading the vehicle may cause damage. Do not overload the vehicle. When you carry removable items, you may need to put a limit on how many people you carry inside your vehicle. Be sure to weigh your vehicle before you buy and install the new equipment. Remember not to exceed the Gross Axle Weight Rating (GAWR) of the front or rear axle. If the vehicle is damaged due to overloading, repairs would not be covered by the vehicle warranty. The load bearing structural information is also included in the Body Builder's manual at www.gmupfitter.com. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 16904 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 06-08-64-035G > Jun > 10 > Body - Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 16914 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 06-08-64-035G > Jun > 10 > Body Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement Front Door Weatherstrip: Service and Repair Front Side Door Window Weatherstrip Replacement Front Side Door Window Weatherstrip Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 16921 Front Door Weatherstrip: Service and Repair Front Side Door Roof Drip Weatherstrip Replacement Front Side Door Roof Drip Weatherstrip Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 16922 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Regular Cab) Front Door Opening Weatherstrip Replacement (Regular Cab) Removal Procedure 1. Remove the front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)). 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 16923 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 16924 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Extended Cab) Front Door Opening Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Open both doors. 2. Remove the front and rear door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)) or Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 3. Remove the hinge pillar trim. Refer to Body Hinge Pillar Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Hinge Pillar Trim Panel Replacement). 4. Remove the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) ( See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)). 5. Remove the windshield pillar molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 6. Remove the weatherstrip (1) from the pinch-weld flange (2). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 16925 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Install the weatherstrip (1) to the pinch-weld flange (2). Ensure that the weatherstrip is fully seated around the door opening. 3. Install the windshield pillar molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 4. Install the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) ( See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)). 5. Install the hinge pillar trim. Refer to Body Hinge Pillar Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Hinge Pillar Trim Panel Replacement). 6. Install the sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)) or Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 7. Inspect the door closing effort and seal to door fit. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 16926 Front Door Weatherstrip: Service and Repair Front Side Door Bottom Auxiliary Sealing Strip Replacement Front Side Door Bottom Auxiliary Sealing Strip Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement Hood Weatherstrip: Service and Repair Hood Front Seal Replacement Hood Front Seal Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement > Page 16931 Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement Hood Rear Seal Replacement Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 16940 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-64-035G > Jun > 10 > Body - Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 16950 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-64-035G > Jun > 10 > Body - Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative > Page 16960 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-42-001 > May > 10 > Lighting Low Beam Headlamp(s) Inoperative Headlamp Bulb: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-42-001 > May > 10 > Lighting Low Beam Headlamp(s) Inoperative > Page 16965 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative > Page 16971 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Weatherstrip: > 10-08-42-001 > May > 10 > Lighting Low Beam Headlamp(s) Inoperative > Page 16976 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Opening Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 16979 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 16980 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 16981 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 16982 Rear Door Weatherstrip: Service and Repair Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 16983 Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Opening Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 16984 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 16985 Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 16986 Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 16987 Rear Side Door Window Weatherstrip Replacement (Crew Cab) Rear Side Door Window Weatherstrip Replacement (Crew Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 16988 Rear Side Door Window Weatherstrip Replacement (Extended Cab) Rear Side Door Window Weatherstrip Replacement (Extended Cab) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 16989 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: Customer Interest Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof > Page 16998 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof > Page 17004 Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Weatherstrip: > 09-03-10-008B > Jul > 10 > Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Weatherstrip: > 10-03-16-001 > Jul > 10 > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Weatherstrip Replacement (Crew Cab) Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Crew Cab) Sunroof Window Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 2. Carefully remove the sunroof window weatherstrip from the perimeter of the sunroof window. Installation Procedure 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. 2. Install the sunroof window to the sunroof module assembly. Refer to Sunroof Window Replacement (Extended Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 3. Ensure that the sunroof does not have any air or waterleaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Weatherstrip Replacement (Crew Cab) > Page 17025 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Extended Cab) Sunroof Window Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 2. Carefully remove the sunroof window weatherstrip (2) from the perimeter of the sunroof window (1). Installation Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Weatherstrip Replacement (Crew Cab) > Page 17026 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. 2. Install the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 3. Ensure that the sunroof does not have any air or waterleaks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions Cruise Control: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17031 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17032 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17033 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17034 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17035 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17036 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17037 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17038 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17039 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17040 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17041 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17042 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17043 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17044 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17045 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17046 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17047 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17048 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > 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Instructions > Page 17054 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17055 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17056 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17057 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17058 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17059 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17060 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17061 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17062 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17063 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17064 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17065 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17066 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17067 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17068 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17069 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17070 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17071 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17072 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17073 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17074 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17075 Cruise Control: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17076 Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17077 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17078 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17079 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17080 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17081 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17082 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17083 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17084 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17085 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17086 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17087 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17088 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17089 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17090 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17091 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17092 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17093 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17094 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17095 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17096 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17097 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17098 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17099 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17100 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17101 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17102 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17103 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17104 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17105 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17106 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17107 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17108 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17109 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17110 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17111 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17112 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17113 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17114 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17115 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17116 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17117 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17118 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17119 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17120 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17121 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17122 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17123 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17124 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17125 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17126 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17127 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17128 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17129 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17130 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17131 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17132 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17133 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17134 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17135 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17136 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17137 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17138 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17139 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17140 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17141 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17142 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 1500 4wd Workshop Manual (V8-6.0L (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17143 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece.